Yamaha YZF750R & YZF750SP 1993-1998 , YZF000R Thunderace 1996-2000 (Haynes Manual)

HAYNES SERVICE & REPAIR MANUAL

YAMAHA

YlF750R &YlF750SP '93 to '98 YlF1000R ThunderaCe '96 to

Yamaha YZF750R, YZF750SP and YZF1000R Thunderace Service and Repair Manual by Matthew Coombs (3720·288)

Models covered YZF750R. 1993 to 1997 (UK), 1994 to 1998 (US) YZF750SP. 1993 to 1997 (UK only) YZF1000R Thunderace. 1996 to 2000 (UK), 1997 only (US)

... _ " ' ... ...".. _ _ ""P* _ _

""""'_Ho,,"'I1'110 __... -...c.I,-......,. .......... "' __ .... "'.., ....... _ "'~ar_

~, ~

... oy

.~1

... , ....... , ......Iange or I......... _~In-""'llInlm .... oopyr\gIoI_.

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- . . , . "-I<.CoMomo 0,32(1. USA

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r"","""""·IIIC,ll"""" _ _

_ _ __

"......,........,...b __ ._"""' ....

""WIn.

~75_La~2,c-.f""'"

_utnry

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....

_,_.1!1~l.PP$o\I..A._

Contents LIVING WITH YOUR YAMAHA YZF Introduction

O ·,

Yamaha - Musical instruments to Motorcycles

p-

Acknowledgements

P.,. 0· ' P - 0· 9 P - 0' 10 P - 0° " P - 0' 11

-Aboullhl$ manual Safety firstl

identification nurnbe<$

......

Daily (pre-ride) checks Et9~oiIlevelcn.ck

Coolant level check Brake "wid level checks Clutch "uid leyel check Tyrt checks Suspension, steering ar.d

finaJ drive clleckl

Legal and aafety checks

PP.,. P,," P.,. Poge

0' 12 0" 3 0' 13 0' 15

P,," P.,. P.,. PPogo

1,.,·'

0" 6 P - 0' 16 P,," 0' 16

MAINTENANCE Routine maintenance and servicing Specib~ A!I(lOIi •• aoded

lubricants and nuldl

Mllintl!!OllOCe schedule Compone!1t Ioca1lona

Mlllntenat'ICe procedures

,., ,., 1·'

Contents REPAIRS AND OVERHAUL Engine, transmission and associated systems Engirlfl, clutch and transmlssk)n

CooIIr.g system Fuej and exhaust systems ignition system

"" P""

3"

Pogo P""

5"

2" 4"

Chassis and bodywork components

F_.

.......

~andfinal ~

P", Pogo Pogo Pogo

,.,

6"

7·14 7 0 21

S·'

Fair1ngaod~

""

Electrical system

Page

Wiring diagrams

P.,. 9·25

9"

REFERENCE

Motorcycle chemicals and lubricant3 MOT test checks

"-

Page REF. 27

Faun finding

Page REF o30

Faultllnding equipment

Page REFo42

Technical terms explained

Index

Page REF. SO

0. 4

Introduction

Yamaha

Musical instruments to motorcycles The Yamaha Motor Company

n

Yamaha namII can be -

back 10

1889, when T(It'akUSOJ Yamaha founded tile Yamaila Organ Manufacturillll Company, suc~ was the Suec"S5 of the company, tnat In 1897 II becama Nippon Gakk; Umited and ma nufactured a wida range 01 ..:I Ot'gans and panos

CunnI! Wood War II. Nippon Gakki's

manufacturing " - wu u\"fsed by the Japan ...... lutll<>t1lies to produce PfopelllKll

and fuel laMa 10< thIIf avlatoon industry. The end ", the war btooglll about 8 huge pL>b!lc demand 10< low cost ttansport and marty firms decided to ulillae their 00S0I8I8 await toollrlg the producHon 01 motOr(:yc l.,.. NIppon Gakkl', liNl' motorcyde went Of! ""I. in F*'>ruwy 195ti.rld W1'o rIamed 1hf1125 VA·' Red Dragonfly. Thl, machl.... a COllY 01 tne German OKW AT125 motorcycle.

'(If

"'a.

fe8\urlng. 'Ingle ~inder two-stroke engine wlln a lour-speed lI_bo .. . Due 10 the outstand,ng success of th,s model the moto>/cyc la operation was a&pa'aled from

Nippoo Gakki In July 1955 and tn. Yamat>o M,,!Of Company was formed. The VA·' a~ recei...cj accIaun by winning two of Japan'. biggflosl fQAd raoIlS, the Moun1 Fuji Cl imbing rBee and Ihe Asama Volcano ractI. The high ....,.. of putNi<; demand for the YA-1 Ieod 10 the deveIopmenl of a wfIokI . . . . of lwo-stroke s
Having made a IarOe ""PaC1 on t~ home mari<eI. y"""""",, _ _ e><ported 10 the USA in 1958 and to the UK In 1962. In the UK the

"gnlng

01

an

Anglo-Japanese

1,11<1.

Introduction agf....,.,,' doorog 1962 _bled 1M sa'- of Japll_ lightweight motorcyct.. and ..,.,.,t.. In BritaIn. AI thaI ~me, compeIJl~ ~W-' the many motorcycle prod"" .... In JlIOIII' ~ reduced numberI ~tiy and by tile and 01 the "~I'''. only the big-lour wilich . . I ..... WIth~~. Ewopoo_ rwno.d In 1968....,. _ y..,... In _ . N!hough DfIginaIIy _ up 10

IW9I 01 two-lIn::Ike r-. r.t..tng mproo..d 7·poOll arak'ng ... as Improved by IhI UN 01 an hydraulic brake on Ih. front wheel 01 OX mod,ll. In"..d 01 Ih. drum ...angetnant VIed and cut "'toy _ _ , ~.

aVlOlable as an opt>on on lat. RO modet. R0350 ..... rliPllC«! by thtt Ao.oa In

no..

,,~

Rumung par ..... """h !he RD

market marine produo;1a, the Dutch baH II now the off.:;'" E.... ~ HMdquanlQ and

rwtge 01 ..ngIe-cyItndIr ~II'OMI. LIHd in

d'tVibulion cenltl. Vemal\a motorcycles ... bull! II 'actories In Holland, o.omark, Norway, Ilaly. Fr • . - . Spain and Portugal

• vanaty 01 ch..... typ"o th. "'101... wI. ......:I m thtt popular 50 cc FSt·E moped. lhe V50 10 90 Slep-IIYuI. RSl00 ..-.::1125. VatOO

Yarmha ... Importtd WlIO ,"- UK by V.man. Motor UK Ltd. IormetIy M'IIUI M~ Sal<M (UIQ Ltd MItsui and Co

1M theOTtn/I...-.ge

__ ongonaIIy • trwlmg

handhng the ah'ppng, dltllibutign and marklJtJng 01 Japanese products Into _t.,n coum ..... UH.mately M,tJoI MacNnwy Sales was formed to handle Ywnaha motorcydM; and outboard ~,

-

Bued on 1M IIICI\naIo!J)' _ from IH motorcycM _allOn. Yamaha hlva produced many Olher products, slOCh . . automobile and bghlwtlghl ..,crafl engmet. m.rl .... engln. . and tor.,

_1.. __

pumpll. ATVa. anowmot>l.., golf COIri. ~u'Ir1.1

robott, I.wnmower., swimmIng pooa. and areher'y equtprnenl

Two-strokes first

an 01 Yamaha', ~ was. whole string ollmovaUOM In ttlll two-.troke won,t Autolube eng ..... lubrication, torque WKluctlon. multH,otltd eng i...... ...cI

P

v. lv.. and power val..,.. kept Ih.I,

two·

.1rOkM at the !Of,1ron1 01 technology Many advanc. ... _ 1Ch~ with the UN 01 rICOI'IIiI .. a ~t I_ _tory, They ......,to!heUSA ... !he ... t~_ .. _· cooIoId 2500c \Won but didn't hrI!he ~ until the..ty t960s ~ FImklIto IIOOtIod a 11Mtrick 01 110111 _ _ in !he 1U&01 ManTT.!he Dutch TT..-.::tltle BeIgiIn GP, Thil.xper!mem ~ ... rt.. to !he ~ 01 the O'o' .. -the-(:ount .. _ ... _tI1at~.-btyin!heTDt. the I'nt 'on .. III'W'I'IIIIChe ..n.. 01 two-l1rokto r - . that ...... the ltandard i...... lor prtVIIt ..... '" ...tIoNII and int_toonaI _

IOf

~....,.

helped V..... he

-..op , _

roed "'gin..... While pI t... ln..

~ theFIMteg""'\>OI\a_~to

the IftIako GP cIaues 10 two cytn:jera. ~ "'otic biUoI dIIed but set !he ...,. lor an unparall.,ed cty"""y 01 ......·produced rteer"I baNd on the uma lechnology as Ihe road ~k .... In the 19605 and 70. the tVt'Q·"roI<. WlgiMod VAS3 125. VOSI to VOS7 250 and VA! 350 fonned!he c:orII 01 IW9I ~!he rrid-70s!hey heel bNn supwseded bV "" AD ~o...Ioped) 125. 250 . ..-.::I 350

IIfI'IIt

V"""""'.

n

!WInS w. . .

TO ..... go! .... ,..-..cooIIng In 1073

10 bacama Iha TZa. the mosl . . - I U .-.d..........- ov...ttta-count.. racer. ..... bu,lt. That . .rna )'Nr. Jamo Sun..... btIcamfI the Inl rldar 10 win • SOO<::c GP on • lQUr·cylinder Iwo·l1rolo. on the new In·IoM lour which ..... , If..cttv.ty I pair 01 TZs .,.. by-lOde. m.....,., ~-r.t;IucIlng the o.ytON 200 .-.d I!iOO _ ~ ..-botad lo351cc. A 700cc TZ aIIo ~ ""'.,.. ~ tII<M out 10 75Occ. 51 .... Sa"- won !he liral Formula 750 wonct t,'1e - one 01 thl 1"............. 01 SuperbIo. - on one in I un The

0· 5

following.,.. ~ RoDan::s won V"""""'I fO"ll world 500 Iltle _ '*OUkI be ~ by Wayne RIo,,..,. and Eddie Lawson beIonI Mick Ooohart and the NSRSOO took 0Yet The air-c:oolad SIng'" and """ cylinder RD f'OIIod b j _ ..... -.lualy ~ by the LC -'as In 11180. f..tlMing bquod-c~ .....,....... radOCll new styllnll. SPirel patt.... CMt whHII Ifill ClInt',.,... .... ~ (YamahI·.~. 01" !he LC modIII.. the RD35OLC. or RD3~R .. h wa' lat" ~l\Own. h.. madl th. most Impact In th • market Laler mod.l. had VPV$ (y,maha Power Valve System) ongInn . .nothar n...t lor Vama/1.a-tItiI _ _ ti8lJy ........ Iocaled In !he

.It.

""-I POflI whicI'I wee ~

po
oparaled 10

maxomum

_tou,

prM"'''.

Introduction

0. 6

The Four-strokes

Y

amana cone.nUlted loilly on two·

stroll, models ...,tilli70 ......... IIM:<81 .... produc..:l. IhW Ii,., /gu,-atroka

motorcycle II _ perIlapl' 'I'...w...• ~ WIth two-atrol<_!hal _Iponed .., ..... move Iota 11M !out-SIr"'" motorcycle market, although their wori< with Toyota

during thl 19601 had g;.eo them a sound _

In tour-atro'" technology

The XS 1 t.d I 650 CC IW'WI-C)'Ionder SOHC .rvroro _ 18'-10 DIoCOtnIo known .. the

XS65O, appMrlng also In the popo .... S£ custom Iotm. V.maIl_ InlTOdueed • IIItH cylinder 750 co ~i'" In 1916. litted in • lport-too,er Ifame and called the XS750, TX750 In IPM USA The XS750 Mlablishtod itself wlOll In ,,,. spot! 10lIl''' clns aNI rwnaIrwd In production with wry lew ~ unIi upIlII.,;I1O 650cc in 1\180 OIher fo\6·all'Ol<M lo/Iowltd In 1976, WIth ,,,. W/'odo(:!lon oIlhe XS2501380101OO _ twins. The XSfar>gfl was atraongt'*'-d 10 1918 byltMoto..-eyIor'Ide<XS1100 The 198(M 111TII!y 01 four. - - . II'1II XJ55O, 650. 750 .nd 900 FOld.

"w .......

~_IheXSI'W"'qe~1O

• .,mll*" OOHC eoginto UIIi! due 10 tile IIIemllOf beh ... d tile

.. location of

'''*

cyllfld~. ~ec t, ontC Ignlllon and Uprlted tlraking and auapenSior1 aylteml_ Moo.ta w.e ,~""bIe inly on 1I....o.rd trun. although CUStom-styled Mn...... ,.... prodUC8CI espeaa/Iy lor the US """"a\ The

....

.............. )(5750 . .. pn:>du<:«Ilrom 't78 10 lte:2 .....:I_l,IJQIed to 850 eo::

Introduction lUS50T _

0'7

"- first.....o.l !rom Y........ 10

hive I ~ ~ AI\hoo.Vl ~ -"I )U moOItI hive rqo, bMn diIc:on\lnuIId. .... on It! " - XJIlOOS and XJiOOS

11.- _

er..-.-n r.;.ca I~ modeII.

The FZR p'''I~ &nCom~_ tllto PIJ" 'POI'i' YIImBhI. modeII. Wtlh the "'ceplkln oj

1M 16-"""- FZR_OO and FZR800 model ... the FZ/FZR75O Ind FZRlooo uMd 2O-vllvl tong ....... two ,"""ust vatv.. '"" IlvM Inltot _ ~ cyIin<Mr. Thill CIIIIOIPl w.. c.'-d

a.- and G"" mPfO""'d IIQ !low 10 the CCIITII:r4Ilon ~ Other fNturM of "'- ""9"" w.... the ..... of down,draught ~

the

.-.d "- engotIII', Inc:IoMd tngIIo In

nm.. piuI. the CI\aI'9' to 1IQ<,oO-cooiong.

UOh I~1

Delisbox dMlgn Ilum,nlum

If....... and uprated o.uspenIion lmj:Irovad lhe bokII', _lng. The a...... tngIne ...... on ... the VZF750 and 1000 modaIs, The ~s concept w.. 11M t.s.. oj V.......•• ' 01".." into four-.troka rec>ng. fQl with

s bika known ~ . . .,... GlnlliI·, ..

fZT50"""""in.TTforrnullotl;lilot_~

the tactory Inampl..:l 10 .,... \hi Hon
w_

nplc",.,....,.

altnougn 0-. was no lull _ . l&am untH 1M. ",,*_It _left to toa,!ppO(ll ........ ~_the ...... ~DaIIIr T.... Y _ WIIICh acorad the 'ac\Ory',1InI1

1ndMduaI.......,..

WotId ~ --. on It'll ...... dIbut ~ of I!NIB. The ridIr'1 Moek 000hIn Slightly.

• t.wt_lOh.

~

_

the.,...

~

FZ750

rather tI1an 1!11 FZR f'o:lmoIogItllOn apacIaIlhIl won racn. The awOl w as s ""'" w,nnlr. mainI)I In 1hI _ of Fabriz;o Pirovsno. lhe lacIory' • . - a.ooc.IIuI _ wIIh ~

~ ~ In the UK. Japan • .-.d In It'll 0Iyt0na 200 I'Ias not bMn

len vIcIorIM. Dut

bWtIIated IntO WOI'Id 01 V.......'. 750L

~

lor IIrf

The vee,\win tngIne I\Ba DeIn the mainstay of the 'IN Virago rangI. Sio'a 198 1 XV. III"" _ p<'OCIuc..:l In 535. 100. 750. 920. 1000 and 1100 ..-.gUl,IIOhc _all_ u"n9 the auaatM bIIoc _-eooIad .-.gIna.

.'Z".

. - 01 _

~

hive bMn

In

the XZ550

0/ haty 191!Os.lheXVZ12 VI!I1tIn: tnllhll moghtyVMX-12 V-Mao<.

0 ••

Introduction 11111. Aossle Gary McCoy rode for Iha we", satellitto team. 80th teams got. win In u.. '99 """"",, and wilh a new 12250 beln\! dev&loped for 2000 11 lookS WI If Yamaha's spirit ol compe1itioo willI!" on unabated into

thol __ MiUeNum.

In the shade 750 and tooo cc 'YZF 'Y1lITIIOhas ahara more than Just. common d ... ~n, they sn are tha sa me reputation. Or 'lith.". lack 01 ~. Neither Is In any way. bad bike. quite the reVerH, but boIh followed and preceded 'Y&r'1'\8ha5 of gtfIate< reputations. The 'YZf75OR first appear'9d In 1993 and H ~ had a ptoblern ~ wM that ~ was thol last of the in_line lours 01 ~s generation. Suzuki's GSX-A750 and Kawa .... ki' . ZXA750 had already ~ arOlllld 101" a co;.ople of year5 and while the Yamaha was just as \IOOd • bike H was a bit late In arriving lor the party. Developed from the old aWOl, the YZF was" Iypical r..linemlK1t of th" older bike bul atypiellily H was a tono·llved model. Th",. was al"" a 'YIF750SP vefsion lor Superbll<e """"9 Wlth clos&-ralio box. single seat, multi -adjustable suspenSion aOld Ilalslkle carb$. nevertheless 'Yamaha teams stili hlId 10 starI with somethlllg much _ _ to a road b.ka th.n an £18.000 homologation apeciallil<e the Honda ACl5. That d\dn·t.top the bi~e winning doIMatic Champlonsl1lps Irt Germany. Japsn aOld the UK 0< linll Eddla lawson ao<:l Iheo Scon Au.HlI dominating Ihe Daytona 200. The Y2F750 also won 'Y.maha'. lirsl ~ d·c.. sinca 11178 Whan CIl, iltian Sarron final ly won In 1994 afler tryi"ll for yea ... Not e bad record. bul !tOIT1ehow the racIng!lUOClt$S c!ldn't tranWIta InlO $howroom \ratnc. CI"" ... buyer. d.d note, h~. thai Ihe sporty YIf made a brilliant secoodfWld buy and a very effective trackday too!. And w~ shouldn'l it? ~ wao IllIhl ... , with a beuer pow",-Io·welllht ratio than lIS immed iate compelitors and wheoln 199511 came with 0hIIna 1Usp&n1llOll as Siandard ~ Wall snarp. than aver. The only other slgnmcant change happened the ume year. a b~ curved radlato< that looked Ii~e ~ came straqrt out of the race kiI. Those clev ... enough 10 buy an underpriced YZF eodad up besk;r.g happHy in the ...nlleted glory of the Supwbike team wh"" Nout Ihe cutt.ng edge

1:;

Vamaha hat alway1J been a sportmoorientated company who ... mona could be 'Aacj~ Improvu th' Breed', SO II', no surprise that thl latest 0..,.,.11011 01 Ilghtwelght oport!Ilers are at the cuttng edge of perIof'fTl!l1lC8 on and 011 !tie lIack. n." Rfi WOO ~ racoo thi\n any ott"ror ~irlOl ~ ~

inaugural yIN. of the World Superapcwls Champiooship, the R7 won B nOC,. in ks debut y.,.' In Wor1d Superbil
tsle of Man Fl TT when David Jelteoi... won \t1fe8o races in a week in 1999.

In Grand Prix racing. the factory tOOk

to ge1 over the shock of WWfM Rainey" crippling accident. and first M)()cc win $IrIce the ~'. ""I~ ....t"...n.nt

.........1 )'MI'S

didn't QQm, until 1We when Simofl Crala. won at Oonlngton Park. FO<" '999. Yamaha refocussed their arnbOtiona and slQII8d Italian superst .... Mme Siaogl plus SpanIsh trIw ell"". for the wctks team, whHa dashing young Frenchman Regis Lacon! and tough

c.no.

Introduction ""ndq 01

~. IibIInga. In lact wMo put up

_ _ _ .......

- . wry good tJikeI iodMd, W. "'al Ihlt when they _ . new no-one ..u qUl~' ...... how !My mled 1n10 the ~ oIlhIngI;. FonUNItaly, has1Iwn put _tIlT» _

~ looked big

.t

aga.nst the OI)p(*toon'. Iop-of-the-range .-repIic:Io sportS!" It 100I<.:I ....... and ....... _~the~ liM • SpOrta ,.,..,.. Or II would ","VI

.....

~.

The

the QPPOIIIlon I:M IheI was mainly dull 10 the capec:ioIa bodywoIt< tIwt COSMI«I ~

Und....... t h tl>lo li~I ... was a 101111)1 reworked FZR1000 mol'" wllh ,n'new Internals, new C'f~ and new gaarboK. ~Ing wM by • big curv.d radiator as lin..:! 10 the .., . 750 ..-.d the cI\IIIaM bears • WILY

close resembiallCl 10 tha smalle< YZF'.

"""'8<1

!tame, 001 aurprllllng II lIMo 1000 In '06. the ~ Itt. the 150 got b only major updoole.1n 181;1 the two~' d-.s ... 10 ......... lhellhe 1000. onty 5 mm Ioolu« in the .. _baM Ihlon the 750. y"" woulcln'\ ; . - 111M bylooloog 1\ them. such is the irnprMalOn of bulk Ihlo! the Thun
-.

The mo10."1 .ng.... charact_t_ .... Iorce tholl 1m_lion, Ttl • • lit. not ~,IIoI« poww on tap. Unlike the

,r.. curw_ '"'-

13,000 rpm 750. ~

tor~

bigger bike has I",,' power - . y . _

am......t 8SOO rpm,....-ty 1500 .......

beft:n Jl'Nk power. Yeo can Slick ~ 10 topand IN ... the gear pedal alone. Try '''''' O
~ and )'QU'. ~down. hole .. the pow.- turVI the InC IirrM you try and puI out 01 • IIow comer With h'l pouitM to _ _ both ~

'fZf

~

gr_'

boMbiI
ttonlung batV-~. V _ ' s fi,..v..... motor naa .... ~ combIr1ed useability wittI ~Iy. and the YZFa are no except"", •. Buy • wei cao.d for ~ _ you' .....10

.-

Acknowledgements

"

lharIkf, .... doe to Fowlers 01 BrIstol and John WlllslI Motorcycles Of Weitlon-aupw·M .... who supplied the mach,.... 'Nt,,,Ml In the IRulUltlQrnl IMlughout this ........ , W, would liiio Iika to thatlk M,ta.! MacI'I'I"IIoIY SalM (UK) ltd tor p.rmIM.Ion 10 ~ C*'IaII'I IIus1r1ItlonI UMdlnthls ........ WldIor~_oI 11"01_ photograp., liiio NGK ~ PII.QI (UIQ ltd tor .uppIyIng the coIoI¥ sp&I1t plug con;Iitlon photo. IIId !he ... """ Rubblor Company lor .... pplylng informlltlon on tyte

0

-

T hInk, .., liso dlHl to K.. Edge who lupplMl II" colo\lr "Inlp• .r.ncy o f the YZf750M till _ _ _ .

About this manual

0' 9

you dIoOe ...... t WOI'k must btl dI:IrM. __ W you cIIooH 10 hoi.,. it done by • dealer. II pro_ In'ormlItlon and procad..... tor /'OUt, ........ntar.nca and ~; _ II

orr... d~tic toIow

and rapair procadllf. to

"""*' trouIlIeoo:::un..

WI ...,.,. you ION thl
an

appointment to get tl'll motorcycll Into I dUlIlI' and ....k"'ll the trips to lea ... it and pic;k It up. Mor.lmporllnHy. I Jot 01 money c.n btl ..vM! by Ivoldlng the eXptlflN Ihe II'IOP mUll p ... on to you to CO"" It, I.bour Ind ovtlrhead costs. An Idded beMl1,1 II Ihe .en .. 01 saUslachon Illd aceOmphlhm.nt 11'111 you .tt ... doing

.... ""....-

'eel

~ 10 11"01 '"Wt" or '"fight" tide 0111"01 motorcyelol _ you ..... n"", on the _ . ~ torwan:I.

We ~k. g ....1 pride In lhe accurlcy of Informltlon gl.en In Ihls rnl ..... l, but

mOIOl'cycl. m.nuleelu.... m.kl .tt.... tiona MId design cl>a"9" durirog the productlon run 01 1 p.rtlcular motorcycle 01 which the)' do not Inform UI. No IllOIlity

e.n btl .CClplld by thl , ulho" or publllhlm, tIM InfonmItIorIlIfven.

0· 10

Safety first!

Prof9ssoonaI meci'>Anics ...... trained In sale working procedure". Howev .... entl!ut!astiC you may be about ge11i"ll on with the job al hand, I.. "" toe time to """"'" thaI y<1'$ oafMy it put at rI$k. A """,,*,,'sllOd< ot attention

rIO'

can resull In an aecldent, as Can ,,,llure 10

oo-w. ~ precaoIioM. T~

w ill elways be f>flW ways o f ~a","lI

accidents. and tha lollow,ng la not a comPf_"",ve I,st 01 ,II dangers: II "intended rather 10 make you aw.... 01 th& riskJ end 10 lII'IOO<>'aoe " 08'" appf08CtllO all wor!< you carT)' out on your bike.

Asbestos •

Certain frlction, insulallng, IleDhng and

olh. products· s...ch as brake pads, clutch

linings, gaskats, tic . - contain "sbestos. EJc"",m, care must be taken 10 avoid lrttalalion of dust /rom such products a.nce ~ I. hua,do"" 10 hea~h, If in
Fire Remember at all ~mt13 thai petrol is htghly llammable. ,......., smoke 0/ have any kind 01 naked lIam" a,aund, wl>&n working on tne "ehiel .., BUI ttM risk don "", end there· " spatk caused by 00 eIectrlcaI ohort-ciwit. by 1W
•

"confined space;" lIigl1ly ">
Remember ...

-".

.. Don't start the ""9,ne Wlth-Out flfst a~ftrtaining that Ih" transmISSIon Is in

.. Don't ouddOloIy """""" the

-,..

prassun!

c.ap

from a hoi COOling ayst"'" - cover it WIth a

cloth and """""" the pnI55UtlI greduaIIy firsl , or you may gel scalded by fI5CllI)Ing coolant

.. Don't atleml't to drain oil unlil you are sure It has cooled suffiCIently to a_Old • Don't g"'sl' any part of the engi ..... or "xhaust .ysl,,", w ithout fll'Sl aacertlllning thai rt Is cOO """"IIh not 10 bum you • 0 .... ·1 ali<)w brak" Ituid or an1 if"",ze to contact the machine's J>IIintwork or ~a$liC

=,."..,.

.. Don't lllpoI"IOn toXIC liqu;d. SU(;/t as Wei. hyd,aul;c f l~ld or antilr....,,, by mouth. or allow them to remain on your Skin. • Don't ",hale dust - rt may b8 injurious to heaJth ( _ A$bastos heading) .. Don't IlIi0w an~ sp; lI& tt UJI right away.

be!or.. """"""'" 1IIiJ>s on ~ .. Don't use Ill-titting span"",. or other tools which may slip _ CDUH inj"'Y

• Don't lilt a heavy component whIc/'I may

Always dlsconne¢t th" battary earth

•

tonninal before wonung on any part of the fuel electrieat Iyatem. and nav... risk Iplil ing ,.... on to a hol eogIne or axl>au$t. • ~ Is reoommended tnat • "re a.llnguislw" of a type suitabIa 'Of 'ual and eIactricaI flfeI is kept handy In the 11""'11" Of wori
Fumes • Certain lu "," ar. highly to~lc and "an quickly cause uncon~lous"""s and death ~ Inhaled to any "xtent. Petrol .apour ~ Into this cataoory. as do thol V"POurs lrom ""rtain solvents such u trlchloro,""ylen.. . Any draining or pouring o f such voiatl l" flUIds should bnouA: Wyou .......:t to run thol engme, a/W8)" de SO in tho! open 8Ir or at "",.1 hava th .. raar 01 1M vehlclfl outside the

""en

-

T he battery

• Nev... caus. a spark. or allow a naked 11ght.-- the vehIcIe's battery. n win normally hoi giving off a cartain amount 01 hydr~ ~ whic!'lis highly axplMiva. b8 beyond your capabluty - get 8S$<stanc. • Oon·t rUSh 10 Hnlsh a Job or take unverlliad short cuts. • Don't allow chlldran or animals in or

around an unattended vehocIe • Oon'l infiate a tyre abo.. the 'ecommended I'r.... su,e, Al>art Itom ov ....trfl!;Sing the carcass, In extreme cases the tyra may blow otl l orcibly "De ......... 1hat the mac/IInIiI iII5UJll>DflOO securely at al l tim .... Thi s i. espec ially Important _ the mach ....... IliOCk ad up to IlId _ or fork removal " De take care when attemJ>1.ing to Ioo$en a olubbom nut or boll. tt Is generally better to poll on a 5I>11n".. ratller than p~sI\. SO that il you slip. you fall away 'rom I he machine raltlar than onto it "Do wUr eye prolectlon when uSIng pow'" tOOl, .uCh .s dril l. send .... ben<:h

,...,..,

tI Do use a barner c"am 0" your hands J)rIor to undertaking dirty jO~ - ~ WIll Pfolect your s k i~ lrom infection as wetl as making tho! dirt ""sier to remove alterwards; but make sur" your hands aren't left sj ,WOlfY. Note that tong_term contact with used er>gII"Ia 011 can b8 a health hazard "De kees> loose ctothlng (cul ts. tIM etc _long h8Ir) weoIt out of the w,,", 01 movir>g

• Always disconnect the battery ground (earth) t...." .....1 beIor1I worI<jng on the Iuet or IIIectricaI .y.~ (.><eepI1Io'tIIn notad). • "possit;Ma, Ioo$en the filial plugs or...whM charging the b.attery lrom an "",,,nal 1IOI.n:e. 00 oot charge at an excessive fIIle or

the battery may burst. • Taka ca" when lopplng up. cleaning or canying the battery. The acid electrolyta. "".nwhen di luted, I, very corr~v. and $hoI.J4d oot be allowed to OOfItoot the ~ or uoo. AI'ways _ ru_ gi<>Ya. _ gogo,""

-.

or • lace ohleld. II you ""'" nMd to prepar. alactrolyt" yourself. always add the acid oIowIy 10 the waifii'; .-.... ;odd the wa"" to the

Electricity • When u.ing an atectrie power tool. that th" Inspection light etc .• always apl'lianca i, correctly connected to Ita poIug and that. where nee ..saary. It III l>'opa!1y gro~nad). Do not usa such al'l'liancfll In daml' condit,on. and, agalfl, bewar.. 01 c,,"lng a spark or applying uces,lv" hftat In the "Icinfty 01 fuat or l uel

""!WrI!I

V8I>QIIf,AIso"""""lhlltltN!~""""

national ....fety standards. • A ""."r. electric shock can resu~ from toochlng CIIfI&in J)8I1s ot !hit electrical O)'SI""', such as the...,..... !>lUll _ (t-IT leedal. when the eng ine I. running or ~ng cranked. particularly 11 components a" daml' or lhe ;n""lal ion ;. defecli"... Wh_ an atectronic ignition "yolem i, usad. Ihe secondary (HTj vott""", Is much higher and could J>rBrIS " De remove rings. wns!watch etc .. before working on tn. vehicle - .sl>8Clally th • electrical system "" Da k... p YOU' work area lIdy _ It i. only too "".y to lall ov... arj iet.. ifill Iyi"ll

.-.

"0,, .~erclse cautlOf"l when Comp"tSSIr\g springs for removal or t"stDl laHon. Ensu" that the t""""", i. ~ and raIaaMd in ~ controlled manner. using sU itDblfl tools w!'Ik:h precIuOe the possibility of the Spr\r1g IIISCBJ>Ing -.1oIantly "De -,-""that any liltu.g tackle u~ has a ..afe Working toad ratlflQ adequale for the

..,

"Do get somllOM to check periodically that aU i1I welt, wher1 wor\e "" th& Vflhicle .

"" De carry out work 111 a logical sequence and chack 1hat IWerything is corractly _bled and tighter1f!d alterw8fdS "De that your vehicle's ulmy affects th at of yourse~ and ot her •. It In doubt on any peOnt, I1"t profassionDlIKMcoo. • II in of IoIIowIrl{J thllso! precau\IO<"I8. you Dr" unlortunat.. enough to Injure ~I, _ madIcaI Dllention .. $QOfI (0$

,,,,,,,,,,,be<

""I<,

.......

Identification numbers Frame and engine numbers

The " - ..n. IUl'Ibtf II ~ Into 11-.. right-hand side 01 the Ita.lng head. The .-.gn ntIITIbIr . . . . . . . Into IIw top oj 11-.. ~anlhlrigtrt......., . . . ot1te . . . . The rncdoII oocIt label is en IIw lop Dl It» Ie/I. hand aub· " ..... _ , unOtor tn. Mal. TheM ......-. IhaJd be 1'8ClCIf<*I.-.d "-PI on .....

_ _ . . they

"*" officIaoIt

'*' t.. In

~

10 ....

w.rorc.

!he ~ 01 • theft. ThIn II

tIIIo.~identi!ic:o t OClrlntllTlblronlhe

In~ side

01 each carb..onInOf DOdy

The Irame ~.I f'lumbM". ltr'IlIone ~aI

ntIITIbIr, carbure!lot idantdicaloon"'-"lber lind modIIoocItlhould be _ kIipIln. ~

I\arIdy place (ouch as with your ~, IoIrcIj 10 that 1floIy . . - . .vaiIabIe whIn purchasing 01 ordering ~ lor I'O'¥ mactW>e. The proc::ecP..orM In thIa manual odenbly It. Doll.- by ~..., model (.g 1998 VZFl 0D0R).

-.

TIlt rn<>
Buying spare parts

Once you NIve found .. the odentrllcllbon number1l • •.cord tl\em lOt enee when buying parte. SulcfI the manulacturen c ~

1Ptdf\Ca\lona, 1*11 _

f,'..

-.doni (c:ornproIM

IhII rnanuIacI ... .wIous c:ornpoIW1Is on IIw rrechIneI. proyDng II'Ie 1O.....nt.n illt. only 'dtIODe..-ty . . . _.,... . . 1:>uyIng the COfTOCI pwll. ~ .. poM,bIe, ta" the worn pari to dw ctnc1 ~ with !he ' ~ catl be maode. Ab'Ig \he trail from the mIrIUfacI. . . to the poWtI shell, n-. _ _ ~ that l11li p.n can.-d up _ !hi wrong ......m.r or be "'ted "'oomIcUy The two . . . ~ new ~ rOt

_10

750 " - 1 ' 1UK)

'"' ,,..

"""'" """'" """'" """'" ""''''''' "fl""" """""

,~

'kS>

"*'*

(UK)

YlF1000F1~

Yl:J'1000A Tlu:1der_ YZF1(l()()fl Thundetace YZF1000f1 Thundentce

1000 .......... (uSI YHllXlCiA(tQ - 49-$Ial1 VZFlOOOR(KC) - CIobIomoII

-. the price 01

.... 01 _

"" """ "., ,,.. ,- . '" ''''''' ..." ," .,,' "" ,," ",. "" "" .'" "" ,"" "" .'" "" ,"'" "" "., ."" '''''' "'" """ "'" ,.W. "" "" 4H51

150 rnodM (US) VZF75OA(Fj - 49-lIate VZl'7MlR(FC) - QII,!omIa YZF75OF11H) • 49-_ VZF7SOR(HC) - c./domoa VZf75OA(J\ - 4ktat. Y2f75OA(JC) - Cal!fcmIIo YZF7!SOfl(l(J - 49·s181. VZf75OA(KC) - cailfomla

you<

000-

..m

~"D7

YZf7SQS1>

1000

......"

....

-

...

--

..

new DfWS, but you can~ alway. be you' .. gerling. Once

worn 1*1 to !he

~s

~_

ya-d Iof' direct

0' "

F.ame No. 000101 ....,

Engine NO. 000 101..",

C15101 ...., 028101-0<1 No1 av",1aIlIe 000101 002101 OO!il01

0151 01....,

"'".,.., _No. 001101 000101 0031 0 1

0281 01-«1

NoII.aolabie 000101 002 101 005 101

"' -

EngIneHo. 001101 000101 0031 0 1 0041 0 1

""-- .. 0001101 NoI ....""_

NQt availa ~

,...-

Not avaollble

No! . vllila/>le

""""""'" "", -

--

~her DuyIng new. used or retluI.tI parta, the ~ I coo.... .. 10 d .... ' dortcl ly WIth ............ w ..... apecia_ in J>an, 1.... you<

....

0. ' 2

Daily or (pre-ride) checks

1 Engine/transmission oil level check Before you start

The correct oil

."rId

'" Support 11>10 molorcy<;le In In "plight I>OSOIlon. USing an ,u , diary WrequltiKI Make u. ~ .. on IwIIIJ'OUI'd ,,; St.llIMtengonelnllM II..,.. for _ _ I'I'WIUI. to

......

• MoOMo, hogIl-revvmg eogrr>M ~ g<MC de!naoda on tt.. oiI_ It IS Y«Y I~ thai 1M COI'Tect Oil lor you' bi~. IS used top up with IIl"CXI ql,lMty oil ollhll fIIlICi\'Ied IyJ>e rod ...sc:osi\y and cIo 001 overfMI

• """"')'11

'*'" •to I'l!IIdI notmII opsratJng

c.uwn: Do not ..... ~ IIddItiI'M .". oIfII wtrII • ~ ot CD or 1Iighw. 01" ..... .,..

-.~

--

_

Calli/on: 00 nOI ... n Iha angln. In .n lHIeltnMl

Sp«II

. uth "

• ,11.~'

Of'

"'"'--

~N~ftOYCONSERVINO

,'-,....." _ . " . . , . . eou/de.....

API ~ SE, SF Of

" '_

&.IrE tOW3O Of IOWCO

U8modoo ..

"" ........ the motOfCVdl undl.turl>ed tor. lew ~ to .-ow the 01...,.. 10 ItJIbIoN

dutch....,.

so

&AE 10W30

Of:>ow.co

·~IOIhIJ~,.."'-""ctIhlJOlibest .... '-'dIO'IfJU#"oondI'IIIona.

Bike care • ~ 1'00 ~ 10 KId oil frwQuIntIy.\'OU shOukIdwc< whifdWyou IIawo any oiIlMQ. If lhln .. no Iigr1 01 oiIlIekage from IhejOOt. 8nd ~ IIMt ....... caAd to. tuning oil (1M FIIUIt Fhdingj.

-W-tO"

Q'>

10" 20"

~ 40"~

! ! ! ! ! ! ! ! ~ :'OW(Jo j

i SloE IOWl49

:

~~bl": "'.el the 011

but lull«l to

1 ::~~~~= =:': =~Ioc~-:: .. ~

W~h

........ .r-.ld I..

'emov
~ ml I...... I. t>eIow 11>00 mInimum 10M, t h. fight-hand I.... ng s.lde-I*"'I (_ et>apt_ 8). 1WncI"" the h..... cap from 1M top oIl1Mt cluldl _

------....

_w.... _ .................... the I'IIOIOfCyde

mnmo.m ..,....... on 1M

~.

window ~WTOWed).

!he oM

Daily or (pre-ride) checks

0" 3

2 Coolant level check ia lmponanl thlt atUl"'HU I, used In the ~t"'" .n yur round, and not just In \he WItIMr Do IlOI lOP till' system up usong _ , .. the ~""' wiI ~ too dilVled

ontv

Before you start II'

~ - . 1TI1l<\VftI of

n

~

----

'" Always check the coojanl level wlllon lIMo

101.......... you 1'Ia.... supply 01 coolant SO" dlStJu.d _,..C<:lO'lOaIOI'Ilnhibled ~ glycol

.,m·frwz•• ~, Nolr. Yam.hIt JPKify rn.r I0Il 'lIP..,.rw C&'! N uaec. our NOr_ ..,.,.... If In dotibl. boll ,~ water tim 01' use

only di31i1111d ..,.r.,

II' Suppcwl the motorcycle in an Upnghl papllon • .-.g" ~.uncI W~ M ........... on ..... groInl.

Bike care •

Use ~ \tie specl1Ied coolant miJlture. It

• Do rIO! ov.tilIlIMI...voir. If the e<>a1lrl1 " algnillcant,>, abolrfo the "FULL· level line a' atrI time. Ilia ..... ,pIus Ihould be elphoned or drained DI1 10 prwenl the pouibIlily of II being "PlIed out of tIw ~ hoM. • tlltle oooI8nC ...... '-* ~. chick Ihe syst... lor 1Mb ( _ I). " no ....... . . found and the level eonlon.- 10 lall, H .. ...commended tllat the ~ .. tak"" to •

Chap,.,

y.....n.dMllrlor.~~.

~~

1

=..:.~!.:\~;: =~:

coolant level up wnh ,tit coolant Fit Ihe cap MClIfeIy. then I",'all the _ t \_

Top

the 3 rw:o""'*""'
FULL Mel LOW 1evel1ina . . ~ on

!hi reservoir - 11 they .r. dllficult to _. _

'-0·

the .--voW cap and look inIIde.

3 Brake fluid level checks

Before you start " Support the motorcycll In an upright pOart""'. using an .... d..,.,. arand II f«I\Ilred T.." \tie ~ until the top 01 the frol'lI ......... cylinder II II IeYeiII poAlbil. The _ mas.er cy\ItIder _ _ Ioco!t.ci ~

tIIIwld the rIght-hand .... ~ " MIIb . . . you hoi ... the COI'I'eo;:t ~ Ikid. DOT 4 ~ >d6d, " W'ap a ..g around the "&eIV~' beooQ work.ci on to ..,..." tNt any spli. _

• Check lot ~ 01 fluid IeaI
rect'l)i immBdialllly Cl!ec:k lhe """al00n of bolh brak. . beftq taking the ~ oro the fOld; " It-. iii evICIence of ... in the 1'1&""" ~ IMI to ..... Of ped .... ~ be bled .. dMcnbIod in CNopter7. •

""'*

iiOOi,", ...

~

come intO COI'ItacI wIIh pMrted-...fK8L

Bike care • The fluid In the Ironl and ru, bf,k, ona!ter cyilodtor ,.....an will drop lIog/1t1y lIS "- brakeI pads _ down.

• "any fluid ~ '«lui", I'I9NI.ci IOIlPng-up tm ". ... ondicaI>on 01 , ~ ... .....-.... '" the~. ~ eI>oo*I bI .....lJga!ed..........edoat

FRONT BRAKE FLUID LEVEL (CONTlNUED OVERlEAF)

mi.,.,....

0" 4

Daily or (pre-ride) checks FRONT BRAKE FLUID LEVEL (CONTINUED)

REAR BRAKE FLUID LEVEL

Ylf750R SP 5 1Iw'o\.9I1he __ rrwI atxwe LOWER ..........., H II 1M LOWER ......... ......,..... cap On

...,;I models, Ihe ,.., t:nke fluid ....... 'Alible body - ~ be \he ....... DIllow !he ...voIr clamp ,..;r.,w (Irrowed) vod .....-oove the cla'np. Support the .--voIr uprIgI\l. UlIXAtW lhe cap _ .............. tt>oo dl~ pIaIe and the

--

"*'

8

!:,~~:t~h:~~~ !e,:.41~~d=~

01'1_

matk. Take car. 10 aWlid spik ( _ Warning prwyioua~.

9

Ens~r.

U,,' Ih' d iaphragm Is eOmtC:lly

_led bel",. Installlrlg ItHt plaIa and Tight ... the cap~, On YZFT50R ..m SP mocIM;, fit '1'4 c~ clamp. On 'YZFl000R models, light.., the mounting IICrew. Ins'" the side covwjl) CO' _I o;owIng ClIp.

(_Chap,. 8).

Daily or (pre-ride) checks

0' "

4 Clutch fluid level check

A •

w.,..;"g:

a,..P<Mri>SI - h_

dutcII

,...,.... _ tione, . . .

~ ~

_~".,...,

fluid

c.n"""" _.,... _

sumxmdIfnsII aurt.c.. wflh .-g.

__

Before you start: "" Support tile motorcycle in .., upright p<*\lon, ,.;ng ." . - y stand II NqII,.W.:I T...... 1he ~ I,11I(II the IQp of 11-. '"-* cyIIncItir ............ ~ '" Mak. an 1'00 ~ .... the QIltI'.cI hyOrBuIic 1Iuod. DOT 4 Is recommended '" WrIfJ. rag .aund the . - - 10 ......

-f

Bike care: •

...

pMtNd....,.,-. IN .... _ _ ~r"" MiI 00 nol .... IfukI ".., /\.N bHtI ~ Of*' f« ........

~

"..,,;.,J,can.,..,.._oIclulctl~

It the ftuid reservo4r requm repeated

topping-up tNo. ill.., indIc.11on of."

~

Uk lOfI'\eWt>et'e in the syst ...., wI\od1 IhooId t.. ""_tlgIted imrnMIIately

" -r "~ ...

~

• ChecII tOt ~ oIl1uld ~ from tI'le hyd .... lie hoM alld component. - II round rwctify....-tl!ly • ChK:Ir.Ihe CII*Eon ot the CIuId'I; I f _ • ~ or ... on Itw av-t_ t-P<>ngy !MIllO lh. lev..}. bletd the clutch U deacribed in

Chap'«:

~ '-'$\ '~

""~.'~"~

I' I" f"111 ......J..:...( 1..1{~, 1

_ SP model •. 'M cllllch IS visible . 1 Or> VZF750R n_ be_u..lOWER ...... !he"'" II the LOWER ...... n . .......,...1'" fluid

~

II'WOugtlIhe_body_ . If

,

....

~

~ ""P clllmp _ _ (.rrowed), then u~w the c.p .n.d .....,.... !he dillphregm plet. and II-. dl~

...... h.... Tak, c. ... to ."'lId SPiI' (_

w...-.g ~.

5 :.~:;cap.:~:-i:'I:;~-o;~S =~~'~ On SP

co_

Of

YZF1~.nd

.::.n !he c.p WIth itS c:IIImp

mocMola.

0" 6

Daily or (pre-ride) checks

5 Tyre checks The correct pressures •

noc

The tyr. ..... , t.. cl\eckMl _ cold ~ aft. riding. NoI,1tIat Iow~

Pf8SWreI II'IIY CIUH the ty .. to slop on ,"rim or comeofl. Hightvr ~ wlM cause ...,.""... __ and.. ..... 1. hIndIlog.

• Usoo . . ~. ~ gauge. • PtoI*'" ~ wII ncr- tyre III, and provide mulmum .t'bolrty and rIOe

-""'

.t...-

lYre care • Check tile 'Yr- c.refIAy t", - . t ..... IImtMdcSed naft or ott- sharp otIjoIets and u _ _ . Openollon ot tI1e motorqocle with

' ~C".I~.ly

wOrn ry.... I, ut... m~y

I'WIUrdoul, . . I,acllon Ind hlndhng .... dIr8c:tIy.tl~.

•

Check the condition 01 11-. tyre ....... ....:I

-..tMo..\ c.pialn~.

• PIck out any or Raila whld> m.-y ....... bec:ornI ~ In IhII lyre 1rMd. II WI. ttwv wII ~ ~ II'lwgh tI1e c.Ing and _ • punc\lA.

--. •

II tyra damage II apparent, or unexplained <>sa ot preslUta .. uptrlen<::..:1 _ !hl .dyle. 01 " lyre fRllng ~(.H"

lYre tread depth • AI the bme 01 wrftlng. UK IiIw ....... mal treed depth be I I leut 1 (Net 3/' 01 Ihe _ r.r-ftII .. 1M WIly .rcund tI1e tyre, with no bM:I ~tc:hM. M.-.y rk*1I, "",,"-, CCIIWdIt 2 mm _ a.pth ..........." 10 be " .... lmlt.Y........ ~ .......... oI

m..-'

.... ..,

mm

UI!m\.

•

R••r

Loading/_peed

36 pal (2.50 Bar)

Rk* and~. Of high ~
42~(:2.fIOa.,

Many Iyr.. now Incorpo •• ,.

w• ., 1M \.-..d. IdenUty the trIang ..... tyre IIcMrwIIII to !he hdicatof t . and ~ the tyre H 1I'II'tr-..l has worn down to thoI ind~l ors ~

~ter

loci',

or "1WI" """' on tile

'*

6 Suspension, steering and final drive checks Final drive

Suspension and Steering •

Check tNt It'oIIrorIl and , . . -...pensIotl

opwaIOIf;

~--"""'1:*IOing..

• Check 11\&1 tile 1'-"'11 ~ amooIhIy '""" 10<:1<.10-_ _

•

Cl>eck thai ,,,- dm.. ella." .lack lan'l

a . c _ , and MlI ...1 11 ..--..y t_

et.pt.,). • II the chain Iookt dry, IubrlCllle It (_ Chapt.. ll.

7 Legal and safety checks Lighting and signalling

Safety

• Taka a ",lnl,llilo chide that lhe t.acIigtrt. \aMogh1. btal<e light. ns\rument IIg\1b and lum ~ .. WOI1< oorrectIy

•

""""'th~. and UlIP1IlIhul wh6-l ,el6&-'. In ell sl~ng poaliion •. AlII<) check lor the

p..m.y.

• Check thai 1"- hom IOUfIds when 1"switch ;. operat.::l • A ~ ~ grMIuaIed in mph

COIl1ICI_offtMpleyt-ChlrQte" 1). • ct.:k that the ..... II>..¢I 011 wtwt the IdI ewiId'I ;. operaIed

• -

1I.~~lntheUK.

•

Fuel

Cl>eclc 11111 1"- Ih,oW.

ct.:k that MIntand

gnp ,olalH

I1IWm IIfl'Ing holds

the "and eec...-e/y up when retrac!ed.

•

Tl'1I. may - . " obvOous. but chKI! th.1 """"g~ fuel \0 compll'. your If you notlOe.q,. o f fuellMk.ager..::dty !he _ _ inmedlaIeIy.

you h.ve

Ensure you I.e \"- correc:I grade fuel 0'I0Ipt.- • SpecII\cabara.

,.,

Chapter 1 Routine maintenance and Servicing Contents

,

Nt l1li.. _ cINnng IUId ...--.l All«rla10f brushes - . -..AI SIn...,. - charging a.n...,. - check

---=-

Ban...,. -.....,.."....

8nN _

~.

"

.._Chapt.,e

"

r.pectlcn_

clutch 1 - . - _ _

29 --et.pr.&

8nN WId dutch mut. c;:yIndIw ....::I caI!*"-- cyIIrIdw ..... -

...-...

..2tI

Stake IIuid le>tel check .

DeIly (pr8-ride) u-kI

. .. _

a

Bl'11cI~-w_c:twd<

1IrIk4I'Y't." - _

8

~..,.;jduldl-lIuk:I~

Clrburetcors - synctwoniMtlorI C1uIdI- chodr. Cluld'l1IuiCI _ ~

check

25 •

. _ o.iIy

10

~

cn.cq

• . _ Dally \In-ridlI) checks

....... check .

~

ayel." - check . CoolIng syst .... -dnaining, IIushing _

Nti~ing

..

Cvlnder~-check

. ........... 18 22 31

DrIve ct..In ....:l ~ - d'IecI<. tdj!..ctmenl IOd IubriCllbOn • EngIne 01

pr-.. - check

Degrees of difficulty

__

~I F"'_. V ; b' begiTIEr-Mlh

~ .me~

1 32

~-oIIlU1dlifl.~. ~-oiIcIwIge.

Engl.r$'tt~ 01 ....... check F .... _ _- ....-.I FrolU IorI<s 01 chMge .

", ",

. _ DeIly (In-ride) d>ed
FUll ~ ... .-.d EXUP ~." - died< Headlight 110m - _ WId .cIjuItmenI Idle speed -check wd ~ NuUo IUId bolla -light.... check SidMtand - check Spar\< plugs - !PI' check _ ""jostrMnI Strd. IofflIr ~.-.d c.toIes - ~ . s~ 1..:1 bearings -1rMPIa1 check and kI;Atmen\ St..;ng 1'-.:1 bearIngs- ~ ~-check

~-~~~-~

ThtotI!e and choke CIIbIM - check • T)ft presswe and IrUd depth.

v_ ~ _ et'«:!< and adjust"","' Wheel bear\ngI- check and ryr,.. - gwotorIII check

w....

., 3

."", ..." " "" "

17 . . _ Dally (J:n-
... 27

." "

,

1·'

Specifications

-Engine

VZF75OR....:I SP rrw:>eI*;

NGK CR9E or 0.710 O.S INn

'''' "',.,.,., gap . '''' ElectrOOe 0II!l '

......Ellctrode

N~

NGK 04'18£A Of

L127ESR·N

NI~

X24ESR-U

0.6100.1 mm

VZF15OF1 r
1150 10 12:50
YlfllJOOR""'ldIIII .

CerbInItor I)'I'ICI'In::ribOrl - ir'ItIIke '4Cl.U'I'I VZF75OF1_ S P . . YUlOOOR modeIt • CltbdeIs

.... -.

mII~.

dlff....::e t:>etwe.l eartIIdItOrs

v..... cIMrancfIa (COLD engine)

'-'--

0.11 10 0.20 rmI 0.21 to 0.30 mm

.

""""....,. ........, VZF75Of1 _

SP modeIt

"""""'" ......., """'" .......,.

192II1II(13.25811) 196p111(13.$2&.)

. Max. differwoce betwewI cyIInd«s . VV: l 000R modelS Max. diIIerence _

c:yIIndwa

eng... .. pr-... (fZFl000A modeIItI

17'9~(12.35e.)

14.5ptl(I.0Btor)

202 pili (13.9<' Bat) 213 pel (1 '.119 BIll) 190pai(13.11 BII) '4.5 peI(I.O BII) 50 to &I pili IUS 10 U2 BII) • 4000 rpm

Cyele parts ~cn.;r,eIeocI<.

20 10 35 mm

o..In "retch IImt (Me text) VZF750A and SP modelS •

150mm

VZF1000R modeIoI .

149.1 rrrn

Re. brake pedal heigtoI (Me text) VZFJ'5OR.nd SP modeIt

"""""-YlFIIJOOR rnocIeIs

EXUP cat» frMpIay .

TyN~(coIdI

,,~

"'~ l107mm ,.~

_

~u:-~J

cn.c:....

Specifications

"3

Recommended lubricants and fluids E"",,...,raosmIeaioo 011type ~oiIcapacIty

YZF150R &'Id SP mod*" 01 d'IIwIOe Oil .nd fil* d\ange

3.0 _ 3.2 _

folawlng ...... 0YeIha0I.' ~ dry ...... ~ f'lM< 4.0_ 'Note rtl8f ttJfI capec;ry of 2. 7 itru (2700 cc) ~ted on tn. Ct8tII
.....

YZF1000A~

""

Oil &'Id 1iIt_ cn.ng. FoIowIng . . . . . ~ - dry

""""'

eng.ne...- Nt_

3.0 Itres 3.2_ 3.S_ distlled _ _.5(W, ~

.".

_

Wibiled

~

glycol rio

l\'Mze. Note: r ........ ~ tt.l """ '-P __ an bet.-d. buf NOT hMd .... ,... If in _ . bDIIlhe ....,., IiBI 01'", only dislM«! ~~.

"""""'-

lW3 &'Id 11I00I VZF150R rod S P . . lW6-on YZF150R lind SP rnodoIII

YlFl000R mociIII ar.kaiclu1chlluld Ortve cllain .

p/ItoI--. rug.

a..mg .... ~

--.

beIwIrIQS .

GewchIoge .....,dutcr.

2.S_

2.7_ 00"

Sl~heId~

SwIngarm &..penIioo

2 .• _

... . ....fIront tIr1IQ leverl

..... bnlke ~tand pivot.

""" .

SA.E 30 to 50 w ~ 011 or cn.in lubricant ""!table lor O-ring chaIna UlhI\lm-baaed mvttJ·~~ ~ IiIuIphideor-

MoIybdootun ~W~~gr-.

Lithium,baSed muItI·~ ~ 10W30 motoroU

MuIIi-t:uJXIM grMM Of dry 111m lubrlcenl

__ M

Torque wrenc h settings

--

1993 &'Id ll11M YZF150R lind SP rnodoIII 1995-00 YZF750R Ind SP I'I'OCJdR VZFl DOOR ITIOdM ~ brake ~.." nub .

"" 'm

VZF150R ..-.d SP modIIII VZFl000R modIIII • Oil
12.5Nm

exuP pulley =-- bclob

.............

Qilrllt.

Steerng held ~ I!djost. nut """,

Sle.ing 51... nut FOfII clamp bob ~op yoke) YZF7SOR and SP models . YlEl000RlTIOdIIIs

---.............

VZF150R &'Id SP modeIt VZFl000R rnodoIII Cooli"ll system dr .... plug(s) Ct~ft ond-c:ov. ICfBWII 001 gaIIIwy boll (yZF75OA arod SP) M... ailp.ry '*'IiI ('(ZF-l000A)

150 Nm

HIONm

"''''' """

10Nm

'''m 17 Nm

..""

16Nm 110Nnl

""" ''''.., """" m """ """

,

,.4Maintenance schedule Nol. :

n.. dally (pt-.-ndfI) chKkI oorHt>fld...

u...,...,..".--...t covers !110M ItetN whlch • dilly basIs............,.. P¥form ,IIe p,.tide iIllP'K'l(In .1 -->' should tt. 1Mpect.d on

....m~ Inr.rv~ (In ~I/OII 10 rile proc«/urIU HS led). inftlllleJ. /lfr.,. bM>w are III. intflf'l"/s teCOmmended by t~

n..

manulKrur... kx eecll ".,rJcuIM opInIlion

Daily (pre-ride) See Deily (pI&-ride) checks at the beginning of this

Every 8000 miles (12,000 km) or 12 months (whichever comes sooner)

.........

manual.

c.v.y aut l1li tIN iMmS """'"" rile 4000 mIM (I!lOOO 11m) checII. p/I4 tIN

After the initial 600 miles (1000 km) II USUiIify ptJtfomwKJ cr. YtmIhI dM/Ir fIIIw lIN

flak: 1hiI _ fim 600 _

r:II!ring rile ~ ""'" cOVMKt In 1hI. m.nl.llli. Y!XJr OWtltl,', ",-null mlY he .... rMfwen//nteM/s Irx 'JOUf model.

(I OOO 11m) from rHIW.

.,.mad out ~ 10 11M ~

~1Mf'.

Q

mall!_ Is

Change the eng.neltransmission Oil and filter (Section 21) Renew !he spark plugs (Section 2)

In,.,..,. 01 eM ldIeduie

Every 300 miles (600 km) YZF750R and SP Check, adjust, clean and lubricate the drive chain

(Section 1)

Every 600 miles (1000 km) YZF1000R

Every 16,000 miles (24,000 km) or two years (whichever comes sooner)

""-

ca..y aut II rile _ _ _ !he 8000 mIM (12.000 Icm) cMd<,

.0. Change the coolant (Section 22)

D

tI Check. adjust, clean and lubricate the drive chain (Section 1)

Every 4000 miles (6000 km) or 6 months (whichever comes sooner)

§

Check the spark plug gaps (Section 2) Check and adjust the idle speed (Section 3) ChecWadJust the cartlurettor synchronisation

(Section 4) Clean and check the air filter element (Section 5) Cheek the fuel system and EXUP system

operauon (Section 9) Check the clutch (Section 10) Check the battery (Section 11) Check the COI'Idition of the wheels III'ld tyres (SectiOn 12)

Check the wheel bearings (SectIOn 13)

Check the sldestand (Section 14) Check the tightness 01 all nuts, bolts and lasten8fS (Section 15) Check the cooling system (Section 16) Check and adjust the throllle and choke cables (Section 17) Lubricate the clutchlgearchangelbrakeleverlbrake pedaVsldestand pivots and t he t hrottle/choke cables (Section 18) Check the suspension (Section 19) Check and adjust the steeting head bearings (Section 20)

Ae-grease!he sWlngarm and SlJspension linkage bearings (Section 23). Re-grease the steering head bearings (Section 24). Change the brake and clutch fluid (Section 25) Renew the brake and clutch master cylinder and caliper/slave cylinder seals (Section 26)

Every 28,000 miles (42,000 km) or 42 months (whichever comes sooner)

-..

c.-,y aut IIIl !hto /!ems under the 4000 mile (6000 11m) chtock, p/I4 rhe

Check and adJus! the valve clearances (Secbon 27)

Every 60,000 miles (100,000 km)

(Section 6)

ChanQe the engine/transmiSSIOn oil (Section 7) Check the brake pads (Section 8) Check the brake system and brnke light SWitch

pM

Renew the alternator brushes (Section 28)

Every four years

t1. Renew the brake and Clutch hoses (Section 29) Non-sc heduled maintenance

~

Check and adjust the headlight aim (Section 30) Check the cylinder compression (Section 31) Check the engine oil pressure (Section 32) Aenew the fuel hoses (SectlOfl 33) Change the front fori< 011 (Section 34)

Maintenance - component location

'.5

Component locations on right-hand side - YZF750R and SP models , 2 3

CooIwII ruetYOir Rtw' brake fluid tesenW &Jttery

""OJ'"

FrotrI~lfuk1~

eoo.ing system pI8$SUffI

""

.-. -7

8

Coolant drain plug In cylinder block /Ole speed adius/fIt'

(YZR>QSP)

10 Englfle/lranSlT'lWioo oil fillet cap

Component locations on left-hand side - YZF750R and SP models I

CJtJtchffuld~

2

Stvering head bearings Idle speed /lCliU$ter

3

(YZRSOR)

.. , 8

AltttrrllalOf EXUP pulley COWW" Coolant drain plug in water

1

-,.,.

8

",mp

_ _ oiI

COoism cklJIn plug in

cytinder block II

Ertgine/rran~mJuJon

,""

oil

,

'.6 Maintenance - component location Component locations on right-hand side - YZF1 OOOR model r-------------------------~

1

Coo/aIItreservoir

2

RMr brake fluid res&voir In-line /vel fiitw Air filter Front b<'8ke It.Jid ~ CooNng system prBAUre

3

4 5 6

.,.,

len. $peIKI ttdjustet COOlant drain plug in cytind&r b/ocJI 9 Enp!neltransmission oil teveJ Inspecr/ofl window 10 EngineltrllflSmisskJn oil

7 8

-""

Component locations on left-hand side - YZF1 ODOR model r--------,=---=:------=:-------------~

2

Clutch !fWd res&fV{)fr SteMng head bearings

3

AJtemator

5

EXUP pulley cover COOlant drain plug .,

1

. 8o6

7 8 9

--

w.,..

""'' '

EnglneltfilflsmissJon oil

dralnp/ug CooIanr dnJin plug in EngIneItnIn5mission 0/1

Maintenance procedures ,., Introduction _ pMotnIOtCI any "*,,1-...:,, on 11 , II>IIn you may want to Illn .II~ begInning and

1 lNs CI'\apIa" is deIIgned 10 hIIIp 11K! tIome mach_nle mllintaln hillher molor<;y<:1e for H'lIly. KOfIOmy, k>ng IWI and peak perlo<-

-.

II>dude .. " ' -, ptOOtdUf«l to -..... thai nothing Important " -'ooI<ed. 11 you till"" 1<41 had II tnajOt WIQIne overmoul, Ihen you IhouId starlIN wogirMo

Ilanclardl, you may wlnt to pick up rool ;", malnt ..·.. nc. . . ~ coincklM wilh the .... xt

from the beginnIng. If you NY'll .. UNcI no ~ of ~I hll;1OI'y or m81nlenance~, you II/><>UId c:ornbInoo .u \tie check, 1m" one Wo-lniIisI ~ lWId th.., loto the malntenaOCfl achadule

2 o.cldlng wt.er. \0 11811 or plug into lhe routine maintenance achIocI .... dependI on - - ' lacIon.. " !hit -..nty period on )'
~

or cal_at InlfIfVaI. II you "IVI

_the~IOf_"""'butMYII

~_

-.

rMC;hIrMI_ haW

Nt'"

:I Belote begInnIng any ....",tenance

.-.pair, Into machine should be CINn'" thoroughly. ItSpeclal ly 'found the oH lilte<, ,park pjugs, valve COY"". aida pe...... ~r.ltors. ale. C .... ning will help . ........ ~ dirt 00.. not QOn\a'ninIIIe Il'ol .-.gIM WId wIIl/IIoW you 10 0I0t..:t _ .-.:I darr\IoI' thai could otn.wIM """'Y go .........uc.I. 4 c.rtain malnt__ Inform.llon is .omeIimM printed on decals ~ 10 the moIorcy<;le. It any inl ormatiorl on the ciecals dIffers from \hal Included herl, uN thl information on the o.c:.I.

Of

Every 300 miles (500 km) - YZF750R and SP Every 600 miles (1000 km) - YZF1000R

"""-

Drive chain and sproetets -

and lubrication

Check

I A IIIIgIeC:Ied drtw chain won" last long and ..... QIIIc;I<Jy damage the ~ket3. Routw.. ct.i'I~.-.:I~ ...,ctnia.III .-.d ............. ~ chain II'ICI sprocIuII

.

2 To ~"-<;k ItItI chain, pi,.... the bike on It .

....., _ ...,. MIlt 1M tnonsmlsaion 01\0

'*""'. 3 """'" up on u.. boIIom "'" "'!he _ IYINS
the

In
-*" ITII(!way - . the two

sprockets, then compare

)'OUt ...................rn

to II'IIIt listed In thll Ctlapter'a Speclfleatiool ( _ IIIus' riltlon) ..... 1M C/I!Iin '!reIet. wtrh W_. ..:Iiu.I",.,,1 will periodically 1M ~

t- beIowJ. Slnoe the chain will

. .ely wear.....nly, roIlM I)iq fc<warda ... IhM waocher MCtIon 01 chain can be ~;

do IN, _ _ I tlm.. 10 eheck lila IIItll' length 01 chain. .. II the challl h •• 'Hellee c:r.in _ • .tthough ~ ill poMIbIe 10 tek. Ihe mtoa.",amant on Ihe bike 11 the ohaIr.guard is _ l i d WId \tie I, "'ken on the chain', lop run, mKlwIY IMII_ !he _kell. Taka tI.... mMIUrfIOTIefIlI In d."--,t place. on II... cr-.. If tt.. chain has ".-tched beyond ,,.. ~mIt, replace It with • new OM (1M

measur_

_.

1.3 Puah up on the chIoIn _ _ 1M

000000000

o

W., .....

'*'

Chap!1If6) II Check th • • n\ l,e length 01 the ch.ln lor damaged ~. loose bnks and pin •. and missing O-rings lind replace with • MW _

II It damage I, lound. Nota: ~ 0(1 old JPfOC""ts, the old c;haJI! " )'011 IIIstlll

_w

".....

~

m.tell a

,.Wand,._ the chUr and .spmcImts as • "I.

11M

~~.ts

-

7 Remove the lront BprOCket cov.. ( _ Chapt.. 6). Cl\ack me teeth on the enolne whoaI sptOCItet tor_

.p'.":I<,,.1 at"
1 _ Illustration) II Iospect the drive chall! sWdar 0(1 the swingarm tor &l
worn (_ ChIpt.. 61.

~ .. 6).

1rfG~


5Inscmeca.""'*-If.ot)rIr;aUon .... _ ""lllected. COt1'l»iOI'I II'ICI galling ~ _ _ the links 10 bII'Id and .......... wNch"'~ ItIort.w 1he d\WI'. Iwogtt\. SUch ...... IhcUd be thoroughly cIoMned and WOtked II'M. If 1M chain is light belw-, the ~I, rulty Of Imked, to ~ 11 wtrh • . - one. ~ you lind • Ught ...... nwk it with hili or poIint. and .-pMt the~, afI.. !hoI biU .... _ rkIdIn. if 1hIocn..·. 8tlII tigtII: In the - . . . .. _ ~ ""'Y be damagMI or worn . Because a bgIlt or lOOked chaI1 can tIiJMgI!J the transmllaiotl output shall bearing, 1\"1 • good IdtNI to .tptac. It with • ~ 0l'Il ( _

0

--

---~

-~

1.7

ChodI_~~In

..

___

-..

~to_iflhay_

~

1

' "8

Every 300 miles (yZF750). every 600 miles (YZF1000)

1.'0. Slacken the ..... axle nut (arrowed)

1.1Ob RlOmoVWed) and alack en end of the 1
tn. nUl oro each

,------.._,.....,,""

Adjustment

Ule bolt on eacIl erld of the brake torque and

\I Rotate the rell' wh ...., unli l Ill.. chain is posit>oned with the light"", point .1 the C«IIfe of ~s botIom run, lh11n place thtI ma.c:IWIe on

s'ack"" the nuts - this will allow eesle< movement of Ihe.....n&el Ba the adjustm.nt i. made (.... IIlustnotloni. 11 SIacI<8n!hol adjuster IocIttM O
Its sOdesIand.

10 Whera fitted. """"ve!hol "phI pin"'om the

a.de nut Slacken the axl. nut (H. illustration). Also remove the split pin from

evenly unW the 8rno<Jnl 01 lreeplay apecffied at the beginning of the Chapleor Is obtained at the <*Iue 01 tI>e bottom run of tf>e chain ( _ "tll.'r. tlon) . Following chain adjustment, cIleck that eacl'I chain adjustmlWl1 matl
,e.r

cle.rance between Ihe adjuster and the adjustment marker - push or 1
~ "N HI

to ehepter 7 fOl' /nformetlon on "h"'~lng

Refer

wheel e llgnmenl.

12 II Ihere Is a dls.crepal'l¢)l In the chain adluatllf positions, adjust one 011l'l9m so that ~s position fs e><1e nullo the lorque seniog ~Iied at the OOgInn;no 01 !heChapter, then lIghten the adjuster locknuts """moly (I" illustration}. AIS
Lubrication 14 II required, wa!lll Iha chain In paraffin then wipe ~ off and allow k 10 '*'I, using compressed air W available. N the chain Is excessively dirty ~ should be removad from the machln. and allowed to loak In Ihe paraffin (1M ChapI ... 6). CII"tion: Don~ UN petrol IgII8OIineJ, .."...", or Ofher cle"n/nl1 flu/ds "'hleh m/f1ht 1IMn1l~ the "'".mlll _IInl1 properties of tha "haln. Don~ "Ia hll1h-PBSs"re war .... (k~}.

The en"... process shouldn't ,"ke lon_

Every 300 miles (yZF750), every 600 miles (YZF1000)

1. 9

"""""ut ..

llYn -Wltdon, tIM O-rfnSroo In !tie cit';" ron.r. could be dtnn~ 15 Fa< routi". iubrieation. the best tim. '0 ...t.-lo;'''1 the chaolll.tl.h ~ 11M ~ tIddetl. WMn the chain .. warm, the 1..obrIcwoI .... ~.IM~~1he IIde plat" belt.. !han wilen cold N ot.: y........ spIICh'iM SAE 30 m 50 W ~ oil: do nor us. eNj" ru~, wllieh m.¥ co""jn ~ts 11>11 cOUld _goo /he O·ring•. ....... It is ~ Tor O-mg chehs. ~ U. Iubrican! 10 II-. _ """"' the Iidto pIa\tI8 - ' a p - not t .... mldd.. 01 ,..... on .... 1_

-.

Every 4000 miles (6000 km) or 6 months pt...,.m any din tailing Into the q i n e _ UM~""...........:I.

1 ~.k. su"

you •• park plug IIQC:k-' fIi the

.nempUng to _ . "'" Is ....pplied In ttle rnotort:yo:Ie', tool kit whictlls ~ UI"IO:Nr \he

COINCt sIZII !)eIcq ~

_.

- • sort,tIIe ooe

~

"""". 2 UsIng

U.. '"lIng side

~

~

t_

IIIr WiMIiIabIe.~"" IhII

I.M around the b. . . 01 , .... spark ph.>g' to

ma/k.,

3 et.dc IIIal UM "'fIin<* location 11 on ..,.;II plug Iud, ~ pull the - " plug cap off ...", spoo'" plug (... iIIu, trltlonl UeIog eat... !he plug terllOYing tool .... ppIled In the bike', toolkll or • deep aookl' type wrr.ch, unscrew the plugs from the cylinder I>Hd t_ illustr1ltlonl. Ley each plug OUI In tWIlontoits~. a'Jy pbg _ _ up. IIfObIem II will !hen be Hly 10 Iden\ofy 1M

--

edg.. and the side elecl'odft should be 01 uniIoIm ~ Look lor ~ depoI/tI. _~«. a.:Md OO'~ inUeIof .....-.d the centre .-etrode. Compere your - " plugllO !tie coIou' ~ plug .-ding ~ I' the ....:I 01 this rTI¥oUlII. Chedr. the ~. !he and the c:wamIc InIuI8\or

w_

body for o;t.,;:ks .00 other~. 5 Ifthe~ . . not~wom. .00 ~ the depoIits..., !)II ..ely ............ with

a .... bNIh. the pIugiI; ,*,!)II ~.oo .........0 (II 1lOcr.cks 01 cI"ipI; . . YIsibIIIIn the

4 InsptCt th& electrocl8s lor WfIIr. Both \he

1nsIMtorI. WIn 00ubI concerning lhe GOIIdftIon

cent" lind IkIe ollClI'oo. thoI.*:I ha\Ie IIQI#'II

01 lhe pIugI, replace !him wHtI new ones. 115 IhtI IXpenM ~ minimal. Not, tha!1hI apar\c ptug. eI>ould !)II _ I d " IV«)' uc:ond

.....a Intervflt. i I - V aooo .......

e C'-"'>g IPIrl< plugs by undbtasbng Is

perm:t11d. pn:Mded you cIMrI the pt..ogs with I higI1l'111s1"1-point.avent al1_11r"1k. 7 BelOt. installing the ptUOI. make sura tilly are the COfNC1 type .00 ilia! fII\gI.oo chick the gill bIlWNn !htI IIIctrodei , _ ~Iuatrltlon.) IhtI \Iatl to lllat spK:ItiId .00 IdjusI . . ~. If the gap mual !)II 'dtUllIId, _ IhtI -'
Com.,....

......,.

'·'0 Every 4000 miles or 6 months

.

"""""""" -

3 Idle speedcheck and adjustment

.""""""",

1 The Idle 5peed lIhould be cn.c;ked and

.,;1""'1.,;1 beI
.n.. _ c.oor.nor. ..

(bIolancltd) ."" wilton It Ie

_aty 100 high

~the

2.8 n....d _

plug . . ,.. . . poMIbIe

Iw'*'O the 1001 by h&nd I Since ,"- cytI_ liNd ~ fI1.Iod.e of ............... , which ill .011 ..-d .asiIy d~. th,"d lila pI\I91 Inlo t ~ heads turning '''e tool by I\arId 1_ IlluttretlOl'1) Once pIugI . . ~-Iight. _ jaC c.n be III"IIIt.d with • spann.r on the tool suppli..:! or • KId<et dIM! 1_ iIIu.tr8tlon :it3b). W• t~

'I'l0l

,he _ric

"",""",II can be applied. tighten plug. to the speC,fIIod torqutl "U'llg. 1twy' _ _ IuIyIWld~ _ _ OIIwwiutighl., ItIem by 11~ 10 1121U'n mt.

_ad

Do not ov.

HI ~ _10 •

I%JiI*1 them.

A, ' ha pllIfI' .... quite ...c ...I'd, yew ~n_ "Ip • shorf.r.ngtflot'_

-..do(,lIeplllfllo ....... rlw..ditil'ltoplM;e. n.._ will ~ _ plug well enrwgh 10 tum II, but • 111 511rt to slip If III. plug lMfIln. to c,... .. In ,IN /loJe - MI....111

-

-,,,,...d '-.ped-

II R..:onnect 1M opItIc plug caps, mtk'fIg lura they .r. """",rely <;'1,,,,...,led to the ocmoc1 ~ C- Ilknotnltion 2.311) Install _r~""~I_cn.c-8)

__

or too low

Befen

~,maQ"""_""'"

.&. "" ."y I•

Wllmlng: Patrol (g.so/ln./ I, .x/Tlmely 10 Ilka _ pt'KlIUfillmmlbla, _ _ rou

'""'*

".rt of Ilta f uel .,..,..". Don't amaII.
clNraoceOl and span. plug II8PI are correct and Ihe Ilr filter I, cllan. AI&O, WIn the ~ back· ... d-Iorth WId _ W!he idle S9MCl er...g. _ IN..
buIba"..,.lhawor1<_, lIIIddorl'twor1<" II 111'"gl wha,. II "at",.1 gal-typa

2 The ...... IIhouId be -' notmIII ~

.&.

_.....

a.

~"""'*'hIl~_.tt.l0

1015 m"",'"" 01 stop·and·go riding. Make ...... t~ transmllllion 111 In ".,tra!,..xI place ttIa motorcycM on lis .tand. 3 On YZF1SOR mocMIs. !he ten. opeod ~ lit ~ on ttIa Wt-Iwld tkleofttla motorcyclto and ~ .:cftHd using • oc.. wdr/ver inun., Ihrough I~ hoi. In I~ Ira..... be.am - !'8I'OOVtI the blanking cap from I~ hOle 's_ Ilh.. trstlons). On VZF750SP and YZf100QR mod*. I~ Idlto opeod sdtUII. ;. Ioc:at.:I on ttIa rIgM-h8nd _ 01 .~ ttIa clllIch co_ 1_ mu,\JlItlOnJ. With Ihe engine idliog, adjust the

th. .-.gina

Idle IPMd by nmk'Ig lha sdju51. ~ ...til th. idla ~ Wal..:! in this Chapt .... SpIcfIicallOnS 111 oblainad. Tum '''' ocr_ doc:kwlp to Incr_ Idl. s~, and an~­ cIod<wIee 10 decrMM K. 4 S ...p tha throllia opao ar>d sflul s 1,,,-, t'-1 rechKl< 1M idle 1PMd. II

'ew

-V,,,,-#III~~.

c.n'

5 II. ImOOIh, _ y Idle boo_, '''' , ....... alI' mi>ctu......y be incot'rect (chick the pllOIocraw Mltmg. - ..... ChIjltar 4) or tha ~ may ~ sync:hroniP>g ( _ Section 4), AJao dleCk the Inllka manifold nJ _ _

I,,~""'k:llwiM_"''''

leak. rw.IIing In ......... 1YD:!I.n.

~"~I.lfroul{Jlll""Yfuelor!

~"""""""oII""""'-'~IO'ifh_ .ttd _ _ WI'Ien rou P«f«m ..." kind at

_m . . . .

worl< on I"a f"si syslam, WI.' uf.ty gill.... .nd ".... • II,. ax/;"I1"I."., .,,/table fOI' • Cia.. B typII ".. (fmnmlIbJa

WMnJng: T.k.

~,

...... "ot to

bum~_or!_""'''''''''''

unll w"en • .,.,..aI"l1 ,Ita g.~ tak...," point. or! Iha Milk. rnanIfokIs. Do nol allow f1ISII 10 build up IrI Ilta _ - - " _petfomIlhad-" ~ •

.xIIII",,'


1 c.mur1l1lor ~hronlutlOll 111 aunply tha ~ 01 adjuIt"'lllhe cartkntIora 110 \hey peas the .. me amount 01 fuaIIalr ml.tu .. 10 cyIIndar. Thia 111 dona by -.mg!he WKwm prOdUC4ld In uch cyllrICItor. carou..ttOfl \hit _ out 01 aync:hroniNItlo

..en WIN

rnuh

In


ru.t

mltaaoe.

irIcreasad engoM ''''penlltura, . . than kINI raapotIH and higt- vi!n'!on "'eli. s.for4I aync:IwonIaing ttIa CIIburatIors. maka IUNttIa_~...cIIdIa~ . .

throru.

...--.

a To ~~ Iynchron;n the carburettors Y<'I' will n...:t I MI of vacuum g.u~. or. mlnomeler. ThaN !nstnJmanlt _ vacuum. arid can be obt_ from

..-.g"'"

mot~ dN!art or ..... ~ .,...,. part, tuppllers. The equipmant uHCI ahooJld ~ tuItabIa lor a lour cylindar angl". ..xl _

complele with II", l'>eCeuary Idap'_ and r.o.. to lit tha taka orr ~ Mol., Baca.ollila I1Ittn 0I1l'11 oync:/ItI;InIII_ ptO(»(in and"",.- for ~ ",.fttlme",•. mo.l

"""""'_ltIafltkro.y....... dMIet".

Every 4000 miles or 6 months ,."

u..

4.11 Pull 1M bI..,klng plug. out 01 110_ for eyII-. 2, 3 ..-d 4 (arrowed) , Star! theerqooerdMl II run unII ~ _ _ I'IOmIaI opIf"ItJng t.npenIt .... then IhI.It k ott. 4 On 1993 and 1~ YZF7!iOA and all SP models, ........... 1M carburettDfll 1_ a..pw 4). ~ !he bIwoking t)O/ts from IhI - . d I points on the ImaklI ~ fA "'-,2.3..-.;14 ~!WId IdtaCh ttw 0IU0e

or manomet ..

roo- 10 I'*" lI$ing .u llabie

lKI.plllll"S 1 _ IUUSlrallOO'l)

~

1M

fuel '-P vacwm ho$8 from the IakH>l! point on No. 1 c'jIinder Intaka menifold aro::l comect 11'4 ~......omet'" hoM. Makl aura 1M No. 1 ~ it an.d'oed 10 the hoM In:m the No, 1 1WI-IwId) ~or manrIok\, a'\d so on, Instal the ca'bo.nI1ora. 5 Oro 1995-00 YZF750A models, retfIOV'I the f.... lank (SM Ctlapt_ 4) . Detach tM three ...::u.m IlONa leo' NoL 2. 3..., 4 _ o r rNniIokb from their cIipI (lIw. . . two _ 00 ,ro. rigllt-Nrld aide and OIMI 00 1M ..n). then pull the bIaokk'og plug out 01 tile _ 01 INCh hoM In lum ISM Mtustratlon) The I
Irion. MaQ . . . . the No. 1 ~ it .rtact.d 10 ,,,. hoM from 'M No. 1 (lell-haod)

....to.nnor,.-.d .. on. e 0.. \'ZF1000R modell,

1_ Chapt'" 4). Detach 'he....,.,..", ' "om their cIIpt ~ . . two hQseI on ..",

lkIa). then pul l Ihe Dlanking pl"'O oul 01 the 04 each hoM In ha'n .nd .ttad1 the gfIUgII

..,.;I

or_._to1hlmUlio'lgI~

union ISM '.ull.lllon.). On C.hlor~ ~., only \hr . . 01 lhe 110_ ....HI ". .... blinking pluG', .... hlle Ihl O\he< one will be ,notehed 10 • union on 0tI1 of the EVAP .)'Stwn components.. MI~ ..... tile No. 1 oaug. • _ 10 II'1II hoM Ircm 1M No. 1 (Iett·Mnd)~._.oDn.

7 Minge I tempowy /vel aupply using III IWdIIary tanIc ..-.::I lOme hotong. a SIlrtIl'lll...gone..-.::l.~kIIe,tfll'lll~ . . tirt.,;I w;!h dImpng Kt;u.unem, _ 10

u..

that tha neIdIe nutter l$1-'S1 .mlnalld but .0 tI\M t!lIIy can 1101 rw.pond to ....-.all c/IInoM ...

...-.. , The vacuum ..aditIO. lor W>ouId bot the ........

r~!he

fuel \¥Ik

III c~

c_ """rr.tlonl

"the

V8CUUI11 r"AIdlngI dotfer. procMd lIS follows.

'·'2Every 4000 miles or 6 months

10 On YZF750R and YZFHXIOA rn<>
MCh ~or. IlIut~lon'l .

In !he ItnIttIe

Iink-o- I-

Not': 00 1101 pl'$# on 1M

SCrllWS whilst .dju,linQ r~. olheiwlae I 1.lse rNdln(J ",,/I 0. obtained. Finli ~ No. 1 cart:llnncr to No. 2 I.IIing the Ieft·NOd 8ynchrontau'lg unl~ tile <8IKI1ng'I ""' the ,..,.... sync;hronise No.3 ctlrbu"Uor to No, 4 tilling 1M rlghlMIld 1ICI'eW. Fif\aIJy aynchrooise Nos. 1 and 2 carblQttcn Ie NoL 3 IIIld 4 I.IIing the ca-rtre

sc._ n..n

_.0II'(ZF1000R~~~

..

ahown .... ng • IonQ 1CnIWdriv« (_ lIIustr.tlon) When ,II the ca~lors " . .ynchronIMod, open and ~1oH the Throlll .. QUIcI<.Iy to Httle \he linkage. and recheck It.. gaugoo rM
11

OnYUTsosP~.""'~ ..ItQf:l

.... balanced by turning the sync;hro
_ _ " IUllted In the

.,1<» """""bII' In !he lOp

oI..,;:t\~. _ :Do1lOlptlllMon!l"­

wfIiIsr wIju,'mg them, Oll!erwiw a '-he rwdIng _ be obr.ined. UnKraw !he bolt. INCurtng the lOP covers on Nos. I, :) SCI'8WI

and 4 carouretl OJll and rf!mOVa Ille coYenI -

No.2 I, the " f.,.enc:4I and t/IoIIld not be .....1«1, FnI synchto
"'*'

readjustlrog

~.-swy.

<_

AirfiMIIfcleaning and renewal

"*' ....

~

I ~ IIw IUOIIIMk ~ChIpl • •).

-.

2 On VZF750R and SP ~ •• J'&flII>W 1!\41 ..:urIng Ih1 .... M..- _ 10 "" r.tt.

ICf1WS

12 When tIM adJUltment I. completl, -'** IIw ya;o.o,m ~ IIw Idle apeed Section 3) unlil 1M apeed

<_

1111.,;1 in thl' Ch.pW '1 Spee~lcal """ II obt1ined Aemo .... !he ga.ugn and refit 1M bIanI
"*'

houM>g, ......aYe IIw CO\f1I" IMId withdraw 1M M. element /rom 1M housing t_

Every 4000 miles or 6 months

3 On YZFl000R modeII. ~ u... ~~ MCUring tile ai. fitter coyer 10 tile lin... ho<.osrIg, thin ~ the COV« rod wittldraw the Ilk .. ....".", ',om the houalng (....

-

,

, Tap the -....., on •

atMousty beyond M1hw ..... ~" WillI • ,-~ InSl all the l i ~ ... eI_ t , makOlg IU .. tt is property _ted - 01'1 VZF75Of1 and SP models

'.13

I 0IItCI<~~~'-~ the W90e and the .. Mer housirIg lor 100M connect..,.,., cracks aod deteriorat ion and ~ K wiIII,.-one N.-aary.

IhIo ...........1 Ii" whtI tile meat. ...,. lacing ~d

1tIfI";:1 10

d<sIodgtI any "'11" !*lie'" of eM, then W ~ • • """_, .-11 todNr1 the ........". dnctiog the air In the opposl" diNction of .."...-.III .o-tIgw C.ulion: " 'ha m.c:tmt. II: 1:On';nlHl/y _ In <*1, 0' condfflotI .. lIN fIIf« -"auld be _MI ....,.. fl9Q<*II!y. 5 Ct-..dr. tt.. *'-, lot aogns 01 d.nIaot. H h ~ .. 10m or c:wnol t. - . . d , or ..

~k

1_ NI",,,,,llon 5.2c1. On YZF1000R

models make ...... the l' FWtlI'l'\al1(" III Itle lop ....:l poInIing IOtWlI
Fuellyltem and

8

EXUP ,ymm ,hook

f~

u... _M.-CCMI'. making ..... the 1'I.Itlber . .

Is In p/.oI 1_ Illul l •• lIon S.2b Of 5.3b). ......181 u.. IullIri _ 4~ 7 ChttcI< IIIaI the coI"clor !n 1M ,It fiIU,,· hOuaIng draon hose ~ not ~ bIocl<ed,

cr..:x-

I/Id o-wn ~ WnecessatY -1tII hose comes OUI of

u... ... IIofI . . 01 IIWI'KIuWIg.

Wamlng:

A

""roI (fI_ _ a}

n

."'~ nam_bI
, •

.~

PrKaullon. wh"" you work

on a'Iy P«1 or filii fvell)'I' ..... DM~ amoIr, Of. _ _ n _ Of' --light bulbs

"""* In a fY'''' pu_type.",..,.,.

n.ar Iha "'otfI' ..... and ""'" ~

w-..

II: pruMlL If 10" spII/ .",. fuel on fOUl' -"1n, I'M" If off Imm~feIy W;lh ao.p and _ . WIIoM)'OII ~...,.Irind 0/....",. 011 1M"" 1)'St.m, _Mt.t)r . . . . . and II..... fA u tlnguis/Nt' ..,/lKW lor . C'I)!yp. fb~" /iq<;kh)

on""""

Fuel S)'Ii t em - check 1 Remove !he""" t-* (Me Chapt. 4) ..., cl>e<;lr. ttl. I.nlr. . Itle , ..... t.p ......:I Itle t~

hoees. and on VZFl000A rnodeIsltle ",. and lhe pump. tor algo. 01 1eal
t.....

~ .

1

"'4 Every 4000 miles or 6 months

~

1lIIY hoses which ... cr.cI«
d,ttr!orated. On VZF750R and SP modlll, lh' !mer Ind pump are mounted Inelda the \¥lk _ ~~ IIrOIJI>d Ihe mounting plat" gaskfll In Ihe bottom of the tank lor IeIIb.

"*

2 II lhe lu.I lap II; leaking. lighten lIMo .......bIy IICI'ew. ....:I mounting bolls ( _ Chapter .~ IIIMkaQe persiIa ....,.,. the Up and diM_bIe It, notong how the c:ornpc:on.nt. fit. 1nspM:t . . comporwJlS lind

replacto any that era "'om or dam~ed with ' - ~ H.... allat"-. oo...wIIoI fit • ..w tap. 3 II tMe carburettor gukal. I," INking, the

sapanlle!y. "" In-line fuel litter. Iit\MI In lho hose from the toe! lap to the ..... pump ( _ IIhJstratlon) . R«nOVtI In. IueI tank fOf acceu lsee~ .. 4). If 1ha d~ Of cIoQgad,

lilt.,.. up....,dlaoDnnect

ottwwIIe rwedI ...--aI. haw I rag hIIld>' to IOIik 11IIiduIoIIueI, then ....... Ina

0<

da/npoI and

from !he

!he _

fill .... ~ the Nt... from !til . - IfId diac8rd It. IrwUIIIthI fWW . . 80 tlwllIa .-.ow poma in thI cho;tIgn 01 ..... /low (il 1~ \hi pumpj. F111ha hoMi lO 1ha on 1ha fiItar..-.d MCUN thIm with 1ha ciImpL

.nor. ThIN.

" On C.lilol'nia modell, <;,-k the EVAP ~ .... _ lor 100M connections.
alae> e ..... ,trainer rlftMl n.ide 1ha ..... hoM oniorI 011 1ha cartlo..of-.nors - I'9Iease the clamp aI'Id de1aC1'11ha hoM. then eareful1V dra .. OUI !he slralner and cl6lln it in new lull ( _ IIu$tratIonaI !Wit 1ha sIntirw" IfId a!tach 1ha ~ InItaIthlluII Wlk (lei a.pter 4~ SIll!

.,." deI.-IotaI>on and ~ them with . -

1I'IIo""'IjIIM..-.dc:to.dctlwttt.._o>o""

or...K-V. Fuel .trainer/finer cleaning and renewal

EXUP 8yt:tem - check

Il.rburettor • .tIould be- dlulaemblltd and rebuilt uI11'IO new gasket• •nd

_I, (_

Chapt.,).

5 CIew1ing of the fuel stral_ .. acMsed Mter " hloh mUeaO" has been co ... '4Od. II II also

....-...y Klull starwtioo II -..peeled. Hthe atralner ia dirty, ctw!ck Ih" condition 0 1 the 1.-- ol )'OW tank - IIIhIrI II evidence of rust. , _ . dr..n and dewl the tank ( _ ~.). Theln-linlfill«lIttedtoYlFl000R ~-.ouIdbe~~.~. it type 0 1 lilt. CaMOI be

dirty _

trw.

~. Not.1tIa1 Y . . . . - . - - l l ' 1 a l tile \n·linll lilter should be .-wed ftVf/IY 18,000 mn. (30.000 kin) on US madeII; 6 On YZF750R and SP mod"'I, th" luel su.lner II mo..,u,d In the tanIc and II; ... t.-J with the lull JlI.rI'1P. ~ the lull tank wid Ihe full pu:np (sM Chapter I). the lilt. to _ .. _ 01 dL'I.".;I tu.I MdIment.

8

~

the

~ If. 1lI0II occurs. the tachomeIer wII be HII'I 10 dlSpllY zero rpm 3 HCOOdI. then 9000 rpm (YZF75OA and SP f'nC)dM) 0< 7000 rpm (YZFlOOOR models) lor 2.5 MODndI, then IhIIICtuII qllll speed lor 3 _ ..pon It ..ill raput the cycle until 1:M ~ IIIWItched oft. , R..-novto the low..- I"rlng 1_ Chapt..- 8) and me 1uII_ (_ Chapter4). 10 Un ........ lhe boll a Heuring Ihe EXUP

'0<

-w..

pulie)l co_ on thl uhaust and remove tM caver ( _ IIluII ... IIon).

remo ... lt>aco......

11 Start the..-.glna..-.d inctNM the reva 10 2000 rpm. The _ II'IouId Iurn. IV. it 11.JrN, IirnuIWMouIly ct-" tNt the puUey on the ............ IIII.n*>g 1ha \/live. If IhI ...., I1.JrN but 1ha puhy oo...~, _1ha~_ check them. and hJ~le 011 ,..paca tr..m wrth rww ..... II --..-y (_ ChIIpIer 4). It the puIev oparalll. but the movement 0I1ha valve is sticky Of not compIata, ' ,",I chack the .,."... and ~ lhey ... good, dIIassambIe the ~el ... e

lor c1eanl"g and I".pactlon ( _

ChI!lI... 4). It the _ doM not opema. refer 10 Chapt ... 4 lor Iunher t_1:I. 12 MNSln the..-nounl 01 IrMpIay irI...::h EXUP cable . . IIhown IfId chadt thai k is .. apaaI'iId at the bIgonrwlg 01 the Chapler (aM -..stration). Hnot, -.ck.. the IocI
~-

a.n

CMcI< li'iio filer lor holM. If ...., _ found, e new pUmp """bIy ~ 1M 'iltMl - 1M fill ... II not IMIiIabIe sepat,Ie!y. ntalllI'IIo tu.I pump ( _ Chapl.... 4). SIII(\ me ..-.gIn. IfId check !hat \here; . . . 0>0 ....... 7 On YZFlOOOR model_, • n..t Sirainer is moulled In me t.ank ..-.d • Integral with 1ha \lip. Remove \ha ...... t.ank ..-.d me ..... tip 1_ Chec:II... 4). CIearo !he gauze ,trainer 10 _ .. _ cI
19nItoon IIW swItchMI >QN', Of

while the IfI!jine II "'""'*'II. 1ha EXUP '¥It.... on 1995-on VZF750A and SP 1T"OOdfIM..-.d all YZF1000R model. performs lis own ..,, -

4. 10 Unscr_ thto boIll (..,.owed) IfId

"'*

--

........

11.12.- ChacI< .... ~In_ 1t1t Is Inooonoct. adjuIt It .. 6a801beJ.1r>IaI1Ing \hoi Into \hoi ..... 1-owedI.., It IockI

'*'

,.......

4.12b EXUP cable

~

MlJustaR

Every 4000 miles or 6 months

"'5

""_"tt.r.c.-.g. tt.I::_:~.:.~~:",,:~;::';~:~~:::;~;;~:~;::~;~:::: into

I~

hole 1_

illustration I , ,:la) Tum

""'~""QU[umiliI_1Igtrt.

tt.'I tum" In by '''~ tum on YlF75OR....:I SP 1/2 tum on VZfl000R modeII., u..n loghl.,. tile Iockrings. Remove Ille POll !rom tIM _ ....:I ctw:k ItIaIIhll frMpIay ~ as I!)eCHI«I ..-d ~ lor IMICh cable. 13 Install the cOlIer and Ugh'.., !tie bolls to tIM ~ HIring specified at IhII beoglnnlng of Ihe lI ...tnot!on &,101.

_.1Ind

ChapI_,_

Englneltr8nsmiAion -

'" """" A

Wa rning;

Sa

e. ,..flJl

...,.."

I

dra lnl"fi Ihe 011, s. rI, • •• "a"sl p/JMo., tIN 611Q'lrN, IiI>d th. 01/11,-'1 c... .,.use _ _ tNlm .. 1 c:or...tent fOI,I\lne .... ....,. fill., c:NIf'I(jeoI fIII1I 1M au>gle molt Important malnt_nc:. Pf'IC*'UN you c.1 piIt10nn on • ~. TIle 01 noll f1I't1ltJbric:ata. the lnIwMI f*\IC of the engImI , t.anatTllUICfl and clutch. buI ~

.... _

7.4c To...-the old IMIIIng w . ....,

Check the condition 01 tt. MaIing washer on the drain pUg ...., dIacard ~ If ~ is da'naged or worn _ ~ wit ~ t. necessary to CUI 1M old one off ~ pIWI , _ nlustrallonl. 5 When 1M oil h9I completely drained. lit the plug Into the ed "mou'u 01 0111_ Ody 0-."") dIecks). Willi 1M motorqcle vertical. oil lew! IIlouId lie blitw.., the

InlltaltIlI _ cap. SlarltIlI ang/ne a'Id l1li ~ ..... lor I....:> or ItnII ........ Stop till ang/ne, WIllI • lew ~. then ctMock II'1e oil level. H ~. ao:Id lflOAloiltotmg 1M level up to 1M ma>:.mum level .... on \he window. Check .-cunei \he drain pUg thallIwto . . no-'

~ ,

•

. . . coolant,. _

•• _

•.

n-._.

.-.d. proIectant. S - - 01 ,he 011 taltM , Ulfrlr", amount 01 _buM and II'IOIikI De chaooed ott.., wllh ' - 011 of \he f'ICOIm1eI\ded grlKle and type. SaYIng • lillie ~ on Ih' diffMence In COil DeIWMIl. 000d oil Md • c'*'t> oil won" ~ oft" lhot tong .... II damao-d. The 011 fin .. s _ be

..

l Ab ..• IIId IIIIow the 011 10 linin

u-.o

ma-imum and minimum ,,,,,81 II... on the inspecIioo window 1_ CWy~) CI'I8Cb,I.

~ •

I

s.a..;"g.lItfMmonoeyontN

.-

r1iff_ be,"""",, good

_

cfIoNp'"

-.1,.., otf

"tN~II~

..

.

7 Every so otten, and ~11y u Yamahe 00 not lit '" 011 praaiU switch and warning light (the system lilled ullH "" 011 "'vIII

~-..iIh....,seoond oI~

2 a.tON changIng ItIe oil, w ...... up the ........ Ihe ...... chin MSitt- Remove II-. ~ fulng and !hoi nghl-haI'Id !airing side

PI'lII i_ ChtIpI.- 8). 3 Pul the motorcycle on ~s iJkIHtanCl, and potlllon. cl
no .... In me WIQioe 1_ MlustrMlon). 4 UMerew lIMo 0;1 drain plug from \he ,-II·

hrd . . . of the ar.I
u-.o _ plug, utIng • new ..... ---II~ ...

7.511 Install

......

7.5b ..• IIId tight ... It to the ~

,

'.'6 Every 4000 miles or 6 months """5«). It II II dvl'I~. to perlOI"m an 011 ~ cIwcl< (.- Section 32). 8 n. old oil drain«! from the ~ cannot be ••uNd and .m.uld be dlfPC'Md 01 proPMfy.

Check wilh your IocIII refu. . di.poU l company. dl.paul lacUity or ~~IO_wMtIwlheyw41

..:::e.pt the used oilier recycIng. Don" pour used oil Into dr.1inI; Of onto IhIo ground. C_ _

= HI

oIdoR~-

Ifll"'-,,_~

lite

then

~/tIfI

.......

_r

_/(-/" (".... _rli".}

In...me"'"

1~ 11on.

Of

is from from

"*'

/t '''1,.. .,.. _ _ <w . " . . 01 _ _ in IfNI 01,

_111""'''~'''''''''S' ~«td!he"""""'''- to lie ~..,

for

~.nd,.".Jr.

" rMn _ pIIicN oIl1tn-M1ra mafwW in ,Ite oIJ, the c/oitch Is ~ ...,...._-.d_IIoIcINd"..t I I"au.n the right-h..-.;I Illiring $Idol panel and tile ~ IIIimg ( _ ChlIpu" 8).

8.2b R... brake pad _ mar/r"t pMJs ""'1 (welt

as ..

uu different

indic:.,.,.. IDcIion

gttlOO'e 1;\11 infO ,,,.

-twM(I; the pad is ..un "'""" the ~ /I no IonQofr visible. Cauliotl: Po no! .now the PMh to _ , to 1M . .,."llh. , fIM Indkaforl COtIUcI !he ...., itHIf .. ,,,.
-.

n.

measur. ,''- Bmounl 01 Irlctlon male",,' ........ ,r>Iog - Ihe m~ Is 0.5 mm, • Rill. 10 Chapl.

7 lor delalls 01 pad

-.

1 A rouIlo& genera l chack 0I1IIe brake aysI ....

will ....... lllal IIOy probIamI ... ~

2

lhe brake Ia_ and pedal fur Improper o. .ough acllon. pl ay. bandl. and Olh. damage. RepIaao any damaged ~ wi1h ..... OI'M t - c:r..pt. 1). CIs-. ..., Iubricale the _ CIlIc~

~en....

e . ~assi ....

badlng ma, .. iallOfm the wear Indlcators-

..., padIII pivots If !heir action " ,1If1 ..-1QUgh ( _ SactIon 161

when they ... alrnoM cantactil'lg the; disc ~sel t the ~ Jn4I be..--.d. The Indir;ators . . visibII by looking .t the bottom corner of the pad. ( _ Illu s trational . Nol.: a n.,-

3 Make lura au brlke fas' ........ Ire 'Ighl. Check the tnIut ~ lor _ ~ Saction 81 ...,,,...... . . . thellliid,...,..,\tIe--.o .. Is COfTICt ( _ Dally (pre·ride) cII«:,b). Look

.scm.

9 .3 Flea .... ~k. ho. . ...cI ~k lOt crll<:k .. IMJlgel and leaking IIuId

avIderrt (_ Sactlon 26). • Make ..... tM brake Hght 0f>If81.. w,*, IhI fronl brake I...,.,. I, pulled In. The lront brake light Iwllch. mw:lIed on !he underside oIlha mBll.~. II not adJuIIab/a If ~ Ilill to 0f>If811 propwty. chac;k 11 (1M before thl .ea. brake ta k.. Iflact II

and .1In\IId1ad belore 1M ridar'1 ""ety II

I Each bfake pad hIS wear 11Id1c.tors that can be vlewMl without removing tIM !>lid. fram the c.Iper. 2 The lu,,"oed In com.t1I of the brat" ~

..-.-y,.,..

5 Make ..... the brake light II activated just

""'"

."'.-

lor leaks at Iha t-. ~ ...cI chack lor crlCl
- - 0·

9 Brake system -

8 Bnlkepads-

Indlclltor

(IrTOW«!)

II.S Hold the brake light __ the adj""'" 1M (81

tA) and tum

aIjustment" necIIUtY. hold Iha sw!tc:h_ tum Iha 1djuIt. .... on the swnch body until the tnkalighl iI.::tlwled when ~ (_ IIlul t.atlon). II lhe brake IIg!>I comes on too koll. tum !hi nut cIockwlsl, If !hi Inke IigIlI ~ on too IOOOn ..- " permerwrtIy on, tum IhI nul antl-clockwlM. lithe $Wolch doesn't opera" t"- brake Ilghl. chick It (SM Chapter 9). 8 The front brake " - his a ~ adjusi. M>ich all. . !he disIanoI of the lower from the handlebar. Each HlIIIIg I. idanulled by • n........ on ItII adjust. which a~ with !he arrow on 1M lever brlcket. PuI!he liver away from !he IIIrdIb8r and tum lhe Idju&t. ring until the Mltlng _ bast ... ~s \tie ricIer Is

oblained (see 1II..1\' I Uo n). Thera Ir. lour HIIings-Hllrog 1 11"""'1htt~IIf'Ir1.and

Every 4000 miles or 6 months ,."

1.7. _ _ _ the dI, ..""", btI~ the top 01 the foon-..t and the top of the b<1Ike pedal . . IIhown 4 tile "",e ll"l. W hen making IIdjustmet>t - . . l1\li1 the pin set 11'1 the level InckeI ill ~ In Its detent haIow on the

.. ttlng

--.

1 CMck 11'4

pos~1on

01 tIM brake pedal.

Vlmalla recommend Ille dillance betWM" ttw top of the brake pedal rod the lop of the ..... ~t IIhooId be . . ~ at the btgorri'Ig of 1l'1li CtIoopt« ~ . . .htIon). " h pedal neigh! Is~ , or It tile rld«'1 prtl8<&nce I. dlllerenl ••Iack"" Ihl cl&vl. IoekroJI on ~ puoIwod, tIW1 UTI the puIhrod UIIing . . . . . . . on the ".. as the lop 01 the rod until the pedal. at tile

'I'Ie """'*

cootct or dn/fed height ,... iIIuI'rlllOl'1). Aller adjustment check II\IIt the pushrod _ 01 sllil visible Nt the ~ in 1M c~. On """""",ion light... the Io<:IIiQI'rt ( _ Step 5).

1.7b Sieck... the IoeI
111_ lhe dlslanc. 01 Ille I.... '" Irom Ih. ha"lilebar. Each ... ttlng is ~I;tlld by • r"IIIITIb« on thI .djust.- wt1ich ~ wtIh tIM .-.-on thI ..... bnd<eI. PuI!he ........ ~ from the IlandIetlIw and I\.m tile adjust. ring unlil ihe ",,"Ing which 1>6$1 aulls Ille rkIM" Is obialMd ( _ mUl tratJon) Thare .... lour ~ -HIt"U 1 gII.-.\tIe~ span.1fId Htlong 4 1M smallest. When maklng aajustment .......... thai the HI In the ~ bracklll is engaged In ita deI .... , I"IOIIow on !he

--.

'*'

11 Battery -

,""k

1 All mod... era fittad WlIh • ....Iad (mainl_nc.-IfM) ballet)' wI"Ilch reqU .... no /TIIIlntenanc:.. Not.: Do nor attempt r o _ /hi t.narr ~ ro cI-* !he eIecIroo')1a ..... or NItety sp«JfIc ~. wrI ~ rhIJ ""PI. ra,vlttng Itt ~lroIyM

Rwno.,.

10 Clutch -

""'"

lNkageand be rret)'~.

...-.

, All f\"IOdMI are ',n..:l with an hydraulic dulch. tor .....k:h I~ hi no method of

2 AIIIhaI IhouId ba done II to check INI !he I""""" _ clun ."Ii t'ght and 11\11 """ CUIng .. not damag-lld or lealdng. ChapI.9 lor I\IIttIer detaiII. •

s..

2 Check the fl uid I....... In Ihl rese.vOI. (lee

DIIIy{pnt-ric») et.cJa)

3 ' - 1 the ....... and

~.

conn«tion. lor

Ca vllon,

s.

a.tramMy caral,,' ...hen

hllldll"rI or worlt.l"rI artWnd 'ha batt.".. 11te ...,tmlyta Is vel)' .,.",tic and III upJoaNa " " ~I Is fIN- otr ..._ 1M NNei)' Is cha'lling. 3 It Ih. machlna Is not In regular u .... cI*:omect the battwy and gtva It ........... o;har~ ..-...y month to ... w.eks ( _

"-".

"...

1 Ct-'< \tie ryr. c:ond~ion and tread de¢h thorou{toIy - _ Dally ~nda) cI>ecks.

Wheel. 2

c-wn.... _ vtrtuaII\' "*",,enaflOI!rae.

but they should boI!tep! clNn and c'-k.-:l peorIodk:llty tor cric ks , "Ii other dlmlgl. AlIKI check ilia wheel ",nOUt and alignment ( _ Cl\llpt" 7). Nev" .tt.... pt 10 ~ dwn8Qad cast whMIs: they !I"IUIt ba rapIaoed wfth new ~. Check !he val"" . . - tor . . . 01 damage or detellor.tlon and hi"" ~ r~ with I new OM ~ nacesaary. AlIKI. make .... the ....... c.p .. In ~and tight.

~otlluid""""~.~

..., _ . The clutdllluid SIlOUId btl dIInIJed tvWy twa y.... (see Section 25). and the """'" repl-.l with _ ~ eIt~ Wthey .....,.., •• 01 - V ftu ~ irrMpIdtw 01 Section 29). The nIII.1er ond sIaV1I o;y! ...... _II Ihould be changed

. ,. _lOll (_

..ery tWO ~.r., or II leakage 1<01'11 I ~ Os IMdenI (sM Sectlon 26) • • ChIck the operation 01 tIM clutch. NIt-.. ill ........ of ... In U. .-pI... (spongy t.IiI l o II-. ...." bI..,;I the dutch ( _ ChIIpIer 2). 5 The cIvtch lever has • apen adjuster wNch

10.5 Ad/IJaUng thI frOfll ckltch ""'" ,pan

1 Wheel baarings wm wear 0_ a period 01 time and resutlln handing probIarns. 2 Support tile motorcycle upright ua!ng an ...........,. ItI"Ii. Ct-'< lor any play In Ille baarlnga by puShIng and punlng the ~ against tile hub ( _ InUlltratlon). Ala<> rotall the wheel and check IhII" ,otatessrrooothly.

,

"18

Every 4000 miles or 6 months , ChId< !of""""" 01 _

""*

bgI'Illl85$ ctlIICk

1 $jnoe 'llbfatlan 01 the ma<:hine 1...0. 10

~ ,.. , ......... ,."." bo/Is, ___ • -'c. IIhouId be perIod~.11y cl>llclced lor p"oI*

----_....

tigh~.

--

13.2 Checking 101' pWy In

If.,.,

Engne(l/l_~

!he_

~_.taIce_dJtcII_.

end M/ot ptKJeI bOI/$

Foolrest

3 pIrf II det..:ted In !he r..r., or Wu-.. whHI _ no! rotate smoothly (and !his Is not _ to tnb or I.............. drag). _ whHI 'oMtIngs inapected lor

P..,~. !t _to_ l oIow'i-Ig·

mus' be; rlII\"IOV'td and _ or darrnIge ( _

"'-".

_"...:1

bOI/$

dIrecI.,;! tIvoug/I tIM h from the b8c:bide. " the h ... bent 01 distorted. ~ !hem

FrMt aodeboltendadlo~_ FIOIIIib't dImp bolls p::tp find bottom

1IWl:J01ol. 01 tIM radiator'a " " " - . . . "-tal

--~

. - - - by

--

disc _

~st 'l"Mm boII.sI""r. 3 II • 10<1:1 .... ........ell Is avalable, .....

~

aIoog

_u.. ~~IlOIII'I_ btIginning

01 _ling \tie

"and lui')' and holding I~

-.a..u.a.d_Itw~"In

If.

~

II.-gged or _

....

11 ......1 be

,.,p.;.d with • rww ...... 2 lubr1cat. !tie pivot r8Qu\wIy 1_ SectIDn 181. 3 The IidMIand ,witch pr_11I the

.,and

motOf'Cyde IMIng IIlIfted ~ tile stand II UIWIdId. ChId< itt. ~ by WIi!dng _ tranerniAion !nIo l*/111li, ~ the stWId tOO~_~.PulIn_clulcII"'"

IIO'Od MIect. 0-. Elc*'
....... ~ 1n• .wI!he ...... _ M 1IIII.-.gIne 1'-'11. _

,wllcII" good. ()Ihr.o,kSe.

~

_ c:trWI ~ Clwptwll).

15.e1o OnVZF1000ArnocIIIs,.-1N _ end car.tuIy 11ft 1M trim paroeI •••

..

.-tel.,;! by bent 01 damaogod ..... _

B ta/{I

I n...,,.,..;I'''''''IIfIIInoI''''''t ~~

4 CIIecI< '1M ..:1101101 for _ . _ 01""" ~. laaQ In the radill:or ...... ttoII-1Ile """Ie deposita 01 <X>OIanI ltaina 001 !he CIUISidIo 01 tIM CON I>oIow tIM ...... Hleeks ... not.,;!. 'e M...-.g _ . 01 low """"'" comptMMd ...

bolls _~piwJl_ SIIOd<_Ind~""

&.uo.,....""""""",1>OI!s Stab lOON ~bOI/$_~bIMd

14 Sldestand ,hod<

c.-.fuIy to pr-.. 1UIue .....

of thIIo .-.d 0Ihef ~

1& Cooling ~Iem­

"""

At..

ili

Wam.fng;

c.rIIuIy wftIIa ~_" tIM air I'Iow II .--.

a.-- ........

5 On 'flFl000A..- .......... the ~ ~ reqund r_ Chapl. 8). ttIough _ _ II ~

2

II ..", c:oc*og

1yS'''' joonl. II nacessary.lIglllon the hoM

15 Nuts and bolts -

the _ _

on I!W

fairing IM1 par.- ..-.d ~ lifting tIM and 01 tIM panel up (HI lIIul tration) . RImcw, the prestu.. cap from till til... flIC k (yzFl000R moOeII) 01 tIdiator (yZF75OR and SP """""') by IIImIng ~ ...,n·clockwiM un l ~ ~ .-..cr- • llOP (HI u.u.ttaliotoa). H you _ • I'IIIaIng IOI.Ind (IndIcaIlng ",... is sdI pr.....-. In the ..,..tam)....-'t unlil ~ stopa. Now ,:nu down on the ClIP til(! conth.II1l.rnrog !he OIP o.mI M ean be retI'IO'o'ed. Check !he condition oIltM1

... M

cooIt
The...pn. _

be cool

' * - ~ IM",.,.,-....

, ChId< the cooIInt lew! (_ Dolly ~

"""".

2 The ..",.. cooling syI(em anould be CheCked !of ~ 0I~. Rotnove I!W fairing AA plr>l(1 r_ CtIapt. 8) and the ,.. ' ank (I. . C~IP '" 4). E... nlne 6ItCh rubbe< cooIIot _ IIoog ita ont,.. length. l.ooI< !of c,ackl. lbo-allons and ot..... damaga. Squaell each hoM II poinll. They VoouId 1M! ..... yet pIIbIe, Ind ,.n,m to \heir origInIIlhtpa ..... ~ . H they ... ~ out 01 '-d. ~ !hem will .-- .....

""iou.

............... oI..,... ......... cnirl.fIuaII

and refill 1hI1JYI1.... with .-- cooIanI (SIll $ooction 22). a..cIc !hi OIP .... lor COCI
.....'"

,6.tk: Pr-.capllrTOWld)VZf750A _ SP .........

Every 4000 miles or 6 months

8 St." the

eng''''

and lei II 'lNCh no:>
operat'lI9 temperature, If*! check lor leaks ~.In. AIJ the coo4ant tempet'8tufl Inc'.... """ beVond normal, the Ian ahQlj!d come on autom.t~11y and the temperature should begin to drop. H ~ doeIn1. ,..,. 10 CI'Iapttor 3 ond ctMoc:Ic the Ian switch, 'an motor _ ,..,

---.

• /I the cooI8oIleveI .. COIl8IStently low, Ind ,..,~ofleak!lc.-.

befound,l'1aYtIthe "I"'~I""" ~~ by. Ya/Mha

17

=~ and choke cables -

..

§

Throttle cable. t Maka lur. tha throW. IIrlp rota'lIt! a.sHy !rom fully closed to fully open with the ITooI III'hHI tUfl~ at various angl ... The grip _ 1'8tUm ... from fully "'I'*' 10 ~

filly doMd wh.-'I reIeeMd. 2 W!he 1I'ro!I» std<s,,.,. .. prot:IIItII)o due 10 • CIbIIo!aLA RImow 1te ~ _ ChapIer 4)

I.

on:! Iubr\e;Ita !hem ( _ Section t 8). Instal the ~ making 8lIlI theV . . oorrectty rooted . If the to Itnproye !hi opIratiorI of thllhroItIe. r.wCllblllo_be~.NoI._In-r

rat.

... _It-.-..rIXltJcl"inlhe~ thin the cabIM., ~1irIg the . - I I I 01 the ca'b.ntl0fa ItId ~ of . . IhroItIe hage (5M ChIopIer 4~

3 With the IIvott'- Ql*aUng 1InOOIhIy, cot-'< for • 1ItTIII" amount of f.....,..,y in the cabIM, measured In terms 01 tile amount 01 twlst,,~p rotation before the throW. and Comparl the ""Ollfll 10 tNt hlted '" till. ~ illustration) H 1I'llncon'ect. ...:Ijwl the ..... 10 c:ond It. .. F~ adj..,"*,~ can t. made.t the thrOttle WId of the cable. PIlI beck the n.obb« ~ on the adjust., I'*> Iooeen 1M IocIK1nc:at~. 11*1 retighten tile locknut. Tum the .elj. ., . in to incrNM

ope"".

CNpc..-.

(_

~...cIe>.II'o~lt.lWilthe~

boot on oompIMIon.

5 It the adjustllf has readied its limit 01 ItdjUltmenl. . . - " 10 thaI the IreepIay is al a m.. lm~m. Ihen adJusl IhtI c able al m. cat"buretto.- end • • 10110.... Remove IN ai, rOll. housing (SM Chapt. 4)...cI the rubber 0;:0-.. the ~ (Opening) cIIbIa lop nut and aIida the caDle down In ItM DtId10 cIIbIa cannot be adjustad . . specified. , _ ItM . . . . (SM ChapIar 4).

s-cun

'·'9

w....lng: Tum lhe hln~ III lhe WIY Ihrough lheir 1,.~eI .. llh " .. angIna Idling. Id/a apaK ahol,l/d nOI changa. If /I do. ., II.. cable may be roulN InCOl'J9Clly. CDn9CI 'h,. concftion I>efon ...." ,he bi.Ir&

A , •

8 Chtoclt that the Ihfottle twlsigrip opera", ....aothly and ut qtJickly when

.-

lin..,. ....

Choice cable 1 II the c;:I\(>Q doll not or:-ata ~ this II probably due 10 , cable faI/I. "*'- If-. cable (see Chapt. 4) and lubrical' h (SM $action '8). I~ the cable, •.,ut,,"iI h 10 H takes the ..-nool*1 _II po<SSibIe 8 II It'Iis tails to imP
...Ilng correcUy at tlla ClI.bu.ello.- end -

"""H' (_

remova Ilia ai, tilt. housing lor Chapt. 4). You can creata _ flMpIay In !hi cable tJy 1IIiCk....rng If-. out. cable ~ .,;;rew on !tool c.rtknnor and ~ !tool cable lurthe< Into the clfomp i _ ,""" t.-lIon) OtMrwiae • . - . - If-. cable-

' . 20

Every 4000 miles or 6 months _

~

may

_..:I dirt (Which could _ _ !hot

c:onIrOIIIlobn;lor_ ..... ~ .. t.I. ,.., 0-.. 01".,. bHllttwbnIs lot ",. t;S1I'IfrfII ,....., pNofJ II • dty-film "'~, ,......~ from"..-,y _ _ by dtrMtnr fIIJf7-..j. 3 To Jubflcalllht throttle and choQ ClI~. '*<::oMecI the cable III Ib; lIPP'I" .-.;I. !hen Iubrlc.l. the c.bItI with • PI'M ....... edapI., orM _1t00l~ . .....-.0_ .... ~ II'Iown (Me . .tntIonII. See CNIpW ~ lor the Itw'oltllo and Choke cable _~.. pro-

.-...m

.......

lulwlcMor. Mag .... _

-.

1001 _

--

~1r'ICIa..pt.2b1hld.llcl'lClblit.

• To lubrlce" ,.... speedomM_ cabI
-

l L311 l ubricoltng. _ _ •

~

.....,.,.. .....

~

_

.. __

Chl.pt.. 9). Ihen w!tI'IdrltW l/'1li 1utltIcaWt

~Irom_ou'

,"- In..... CIObia With motor 011 Of cable

lub!ican1. Do rool lubricate the upper lew ~otthe_

up into _

.. _lubrk:atttmay!r''''

irIs\t'Umenl head.

, s.-1hiI controII. cabIM and ¥8IIouI ott....

CIOfI'\POf*lII: of • motorcyCle . . ItJ
et.n.nt.. IMy ahouId be IuDricllltid I*lodlcdy to ....... u" and !routH-free

!he'

2

The~.

dutdllrOd ~ .......... br\ll
pedal, QNl'Shi!t 18_ Hnkage and liGHtano:!

p/YoIllIla
PvoI )oInI gap5 iIIId wi usually WOIi< 4

W"'f

Into the . . . wt.e fIooocIion OCCU'I. • moIO' 01 or IIghI ~ .. bIing UIed, ~ It IJ*YIgIy

, The .... penI/on CO9IIf8.111>g eond~lon to

.......... riW "'-'V.~. worn or ~ '"'~ partl dec ..... IIIto motorcycle', IllabiIit)'...-.dCOl'IfOl.

Front auspens lon

Rear suspett810fl 5 I"'I*'! the __ -'IOd< for IIuid leakage and IighIMss ~ its mounl'''OI. If leakage 1ll1ound. • n...... shoc~ .ho~kj be Instan.d (aM ChapI.6j.

e

2 While a\.lOdlog alonOtlde the mot~, apply \he Iroot tnlce and puIh on 11>10 I'l.and~ 10 tomP""'" lhe forb _ ..

WrIh the aid 01 . . -..IIItanI 10 support the Dilla. comprest 1M __ ~ IMI¥WaI

IllnM, See II tt.y ~ up.ancHlown ~ without bnIing. "l:WIdrog .. !WI. "'" foo'k8 thouId be dtsassembIIod ..-.;I qp.cted (sH ChapI.. 0)

wIIhouI t.IdIng. " WI)' birdng" felt. the """'" 00' laulty componenl mUll be iderlt,/Ied and ...--ed. n. ptobIwn could be .... 10 IIi!hw

3 Inspect tile area around the ous, _I lor sig'" of oIIleakaQe. carefully __ ott tM duat seal UIInQ a IW·DIaded ~ and lnapect the .... around the Iori< _ I (He ftlustfatlonll W-...., .. ....-s.rrt. _ ..... must to. fitt.,;l I.- CMpt.- &). DIede !hot kIfI< ~1or~ •• ~_PlIIlno;J ..

components 00' the IwIrIgarm compon,,,,•. 7 Support lhe rnoiOO'cy.:fe uting an .u ~ 1I1ary stand so that the __ ""*M '" ott the ground. Grab the ...... ngarm end rocl< It from 111M to 111M - u-e Ihould be no discernible rnavement at the .... (Y....- specify •

"*'

hmM. It aIIoukj

.no... up

and down ""'Y

lhe shock abeort>w. thoI .... spwlSion Ilnkagil

_I.-et.pwe).

rnaunum of t rnml (He muatratlon}. " tt...·1 • little moYWTWIt 01' • sight dicIdng CW1 be _ . It\IfIeCI the tight..-. 01 .. the rear suapoonalon mounllng _ and nut ..

4 Chtdt the light.- ~ all ~ nul. _ bolts to to. __ non. have WOfktod 100M. retemng 10 the torque senlrlgS specified lIIlM ~ 01 CIIapI. 6.

relerring 10 the t~ M!tingI ~ at the beginning 01 ChaPI. e. and ,,·che<:1< 100' movemenl. Nlxt, grup the top 01 Ihe .... wheel and pul ~ upw80fdl - 1Ilere sIlouId be

_

will ...... pNfTIM ... ...,,..... "!hot

d.m.ge '"

u~

new tutlel aI'IOuId be

......---.

Every 4000 miles or 6 months

20.80 .•• I nd on 750', tha clutch .---voir bOlt (arrowed) and displace them

2004 Checking lor play in the It~ hHdburingl no dO$Cllmlblt fr-.play before the ahock abMlfber bIgInl 10 comprua 1_ IIuItnotionJ. Nrt ~ .. In ~ check iI>dII;Il" ... om bN
e_

• To mak_ In accurltl Issaumanl 01 thl IWlngarm baaringl, .....oIl_ the r_ ""'III Cl\apt. and tholl bolt MCuring thl It.IIC*"*>n IinUga rWa to the aMIpm ( _ Chap!" 6). Grup the .... 01 thl ,wlngarm wtth ona hal"ld and ~ your othar har>d '" the ;.lnchoo 01 IhII .~ WId the lrame. Try to rr.ov. the r_ ollila .wlnglrm Irom

e_

n

..o.to-wa. Nrt _

(play) in IN t>IIInngs

Ihould be fall " mo......,..,1 bah..- , Iha ~ and the Ifama " till front K then!

II any play IhII 1"NIngIrm win be Ifill 10 mova forward and backward al the front (oot from ejde-to·a.de). "'t.. natlvely. maaaura Ihe amount 01 freapllY al Iha sw"'9 ..... end v........ ~ ................ 01 t mm. Ne>
binding or rough spolS. II Iny play In the IwlnglrTn Is noted or II the .wlngl"" don not move Irelly, th_ bean",,1 m.... t be fen"IOVed for IMpectlon or r-"II 1_ a.ptlr6).

' - 21

I ThII motorcycle Is eq ... ppad wUh caged bei ItMling head Deltin~ .... hich CIIn become dam", rough or 100M during 01 the~. In P t _ - . . worn Ot 100M ---..,~ can CII'- 1I-.t111 .... oDbla - I

""""* ....

condition thaI II polent~ ~ Check 2 Support tha motorcycle In ... uprlghl poII\Ion ""ng sn aul(lllllry lIand. R.... the fl"onI wMII off Iha grtIlJ"Id iIIIhef by tw...-.g.., _ ' - " push-. 00 the ..., Ot by pIaQng I IUppol"1 und .. the engl/\I. in whlch CII.. rlon'lOVl tha low.- fairing Ilrat Chaptlr 8) 3 Point Ihe lront wlllll sl"'ght-,1I1ad and aIow~ move the hllOdl~ Irom Ik\a-IOaode. Nrt dants or ~ '" ItM bNrng _will belelt and the bars ... r.:.!..-

""""" •

..-

e-

grasp IhllIorIc alkMfs lIOd try to pI.Il and puah them lorward ... d backwerd 1_ illustration) . Any looseness in the It"ring hlad bIerIr.gs will be lilt IS front-to-r'" mo...-t 01 the forb II play is felt In thl Ne~ t.

~ ~the.-..g_.!oIowL

AdJu.tment 5 RamovtI I .... 1l,ii0i '-"" ( _ Ch.op!Ir 4) Ramo .... ilia lalring 1_ Chlpler 8). Nota: AIIhougII !r h nor $llicrf)' . - - y to ,.....,... file fairing. dOOt{/ "" wJI PtWIfII file pogiOJ/iIy 01 a.m.", should a too/ slip. A/teJ1l1wve/y. l1Id _,"-Slay.

S Unaaew tha bolt MCIIIVIO tha front btaka master cylmder. Ind on VZF750R and SP models atao the dutch master cytinder. to IhII tlJP yolcl and dIsplace It/lhem I_ 111"l lra lionl ) Keap the masl. C)'IIndarjI) upright 10 pt--.t IkIId ~. 7 R _ _ lha btanklng eapa trom tha ~ poaitioning bo/tlII UUIg 1\41.

bladed

IlCrawdmer

Urecraw the

!_

a"""

illus tration)

~ ~lIoning

bolts, then aIaclIts IIIICI ilia lone clamp bc>Its in IhII lop yok_

-....-

!_

20.7b .•• than 1.II'ISC<ew tha I\andIaOIr" positioning bolt to'J. tha hllndlebar clllfTlp bah (8) a nd tha IorI< clam9 bolt (e) on each llde

1. 22

Every 4000 miles or 6 months

. ~tt..~

.... nuI_"""""

It Illong ",i1h Its w",,*. ,..,.,... fitted , _

iIIuWatIonl. , Gently •• se tile tOIl yoQ IIPW",o. off

I~

10!1< tuDei and posIIlor\ It~. vsng. "III 10 Ptoteet the tank Of olh.. compoMllta ,_

"'........

10 Raomove the tlbbtd Iockwast., noting hOw It rotl, U- ~ and ........... the Iocktlut using .m.... • C'''I*\ner, • peg apanf* or • dtfft Iocellid in one 01 \he

r\OlchH ,.... lIIustratlona). Remove tile rubbef washe< '1M Illu• ....uonJ.

..:Ijualer nul and 1M wr....::h IOCI<et in \he e.pecial tool (_ IllustrHlon) . Now aIaekton Ihe nut "" !hal It It ~. then tIghIen It 10 II'W final IOt'l"" Mltlng tpeCH~. Check that thoI II-ng is .un able to move freely from IkM 10 lido, but _ .. 1rwpj8y .. eliminated. 12 II the V....... t ..... is noI • ...-..-. ueIng t/tIIer.c.~,.peg-..-or. CIrlfI. Ioc
sI_

01.03) and • 10ftIIM....."a, _.-.qulr«l II

lHUStnltionJ, TNt P'*"ioads tho! ~. Now tIIacken !he 001, then tlgt>ten It again, N!\Ing It .0 \til' all ',MplIY II jut! ramo..,..;! ..... 1"at.-;ng ill able to move It.,..y from aide 10

the i0oi ill ......... Iht...,...,!he ...... nul. ~ IighIan It 10 ... IMJ.I torqUe ..ttJng tpeClfied , I 11'1, beglnn"'lI of the Chapler, mlkll".g lUre the torque w.....clt h.andle ~ I' otghl 'lnglell (90') 10 Iha line bet"'"" th'

.... TodolNltigh1entt>e ..... r:rty.IiItII • • time. and ,II.. Melt lighlerung NPM\ the chicks 0II!IDd IbOvII (Steps 2 to 4) r i 1he ~ . . ~ __ TheobjKtillto . . ~ .,;!just.. 001.0 \NIt the bear\ngI ... l.W1der

11 To adjust 1M t>earh'IQI as

e.pecll~

by

v......... ~...w:.1001 (PI, No. 90lIIIO-

-. w_

• . . , IghI mdInQ...... ..-.ough to _

Ca"tion: Tah grut

_w,.

c.,.

Illy

not 10 apply

IIXcenNe b«;a"N IhJ. will """N I'f'8IMt",. (.nu,. of u..l>urlng.. 13 With tile bearings eomoetly adjusted. install the and the lDc:l
dr!!'t unm tile notc_ align. bu1 maQ ..... tile ""iust.. nut claw not tum as ..,... IlIItall tile taI:)bad Ioc~ a:> IhM tile IQ lit nto the In boIh the locknut and adjoAt. nut t - _tratIon 20.10.}. 1.. r~ tile tOIl yoU ontO the "-""U 11....

not"'"

(see iIustrItIon 20 .... IhIJl tosIIIIlht WISI'lIr rwn.r. m tedj and 5t~r>g 51em nut and tight"" ~ to tIw IDg ~Iad alltNt

Every 4000 miles or 6 months

'·'3

begIir'oniI>g 01 the CMpIIlr , _ M....htion.j Now l~hl1ln both lhol tone clllITIP boll. 10 the 'l*'d~ t~ Mtling 1_ MI .......Ilon) . 15 lnaIaIIlt1e MndIebIr po./tJoning bolts rod light.., them to the specifIMIlorque settJng, ~ t9Mn the ~ $/TIp boItIlO the II!*'1I1aod torqu. , _ 1II"'trlllo"I), RIttle ~anklno caps Into lhol positioning DOlts 1_ Ilut ...MIon 20.7-1 . la ntoI the from brtoke ...... c:yIIndet,...:I on VZF150R .rod SP !'IlCJd* II'1II dutch . . eyHndow, onto the top yok. and t;gllien the boft(" IKUlIIy 1_ llustratlonl 2O.S. and b). 17 AI-check \h' beRt'lng Idjuetment .. dMcrIbed &bow and r&-adjust " ~

Every 8000 miles (12,000 km) or 12 months CaI7)' out ,II tile It~5 undfJ, the 4000 mile (6000 !em) cI>«JI. plus u.. foIowtIg:

21~ oil and lilter change

&. I

Wlm/ng,

S,

~

~

r:_,. '" 1

...hM

min/nil the oil, •• the ... h ....t • pIpN, Ihe ~ ~ the oil /fNIf un c............ bum .. 1 Drain the 'r>gl"t oil &I dl",rlbed In SIoetIon 7. St_ 1 10 5.

2 Now plaoe the drain tnly below It1e 011 fin .... wl\k:h if, . t the Iront 01 lhol eng,ne. UI'I8CI'_ the oi .... uaong _titer...-lng su.p, cot... Of -wdllnd tip any rMIOue 01 into the draWl tray lIIu,tr,tIona). WIpe any oR ottIlie IKhaus! plPM to Pf ..... nt 100 much amok,

,t"

when)'Ol'tUlrlIl.

3 s..- dMn engine 01 onto th& nbbIr MIll on the new fill.,., !hen manoeuvre It Into pOMion rod _ ~ onto !hit .-.gine until the Hal jus' lINts ISH iIIut t'ltlons) . If lh' correct 100II •• Iv";labIe. 19h1eo the till. 10 the lorq .... Nttlng speclIIed ,I the ~

1

1· 24

Every 8000 miles or 12 months

of In. Chllpl.. I _ 1II"ltr.llon). OtI*Wl ....

I9tten the till.- as tlgIII .. p<>SSibIoI by hand, or Oy !". nurnDW 01 I....... ~"io
"rap or ~"." filler .....ow"" tool ro light.n the (oft. . . . you

wIII~!I.

WIg''''

4 Refill \he 10 \he ptOpW daiSCribad In Section 7. S\epl61O 8.

......

U

21.3b .

Every 16,000 miles (24,000 km) or two years 01.1, d II-. ,,...,. ~ II-. 4000 mile (6000 krr1J aro l1000,,. ('2.000 ~ dIacIIs: c.rry

22 Cooling system -

,,

-.utt_

draining, Hushing and relliling

A I

-

dort~

;.

'"

w.,."ing: Allow 1M ~ '0 cool compIe,eIy parlorm/nQ 'his

be"'" malnlenane.

_.,,_

with)'OW" PitI or

th.

1i:!

'h.

malore),<:I..

o~ralion.

AlaD,

to come Into conlKl ~r.d

Rlnu

0" of

of

I/IH/.

/m~lal.'Y "'llh P'-'t'Y ",.. I.r. Anlff_. ~ highly lo.>:lc " infl'dl.od. N ...... ,.,.~

n._,

ctt-.n.-.d pel. _.nner.d by .".." and m.y drink /I. Chack wllh Ioc.oI .ulhorill•• (counclll} . boul dlspo.lng 01 .nll/-..z.. Many commun/l/., h ...... cOllecllon e.nl,... which ",III I •• Ih.1 ""~ II diIpoud 01 ""eIy. Anflfr'Hn ~.r.o combull/blot, aD dort~.tor. If neM

.nllf-..z./ylno .oround In .on open

conl..1n« or ", puddla. on ,,,. floor,

Dr-slnlng

1 ~amov. In. low., 1.lring and th. 'airing OlIo. !Mon.... In. ...1(1) and the rlghl·h.nd . . . co.oer (yZF1000R). aide ~ (YZF75OR) or _ cowling (YZF75OSP) tChIpI.. 8). On V"ZF1DOOR modeiI rerrocMI the lalrlng II requlr4ld (1M Chapt.. 6), though Kent I. r.. lIOn.bl. by removing the rMr --.. on the lairing 111m panel and c:arafUIy

I,"'ng \IIa and or II\of !Monel up 1_ ~ 1. . .. Aemowlhe pr-... "'IP !rom Tha filler _ (YZflOC1C1R m<>deIl) or IWIIa!or (YZF75OR W"Id sP moOIIII) by tImng ~ anTl-ckx:kwl ... unlllll reaches a stop (I" l1Iullr.llonl 16.Sb .nd c) II you h. ., a I'IIUing _ (IndicaTrog tt.w. .. .ell prwaora In the sys.....), _ umilir ~opL Now pt.a down on Ihe cap W"Id COI'IIlrue tImng the ~ unlll H can be~. AIto.......,....the f ilar cap lrem the c;ooiwll rMerlloir

2 Position. IUIlab1. COI'IlakMt

~lI'IlhII

wa'" PII""4'. Aamovto !he ClOC:MnI
/rom \he WIlt. pump W"Id allow !he coolant: to wmptelely drain from lhe Iystem !_ IIlu.traUOtII) Rela in tn. old _ling w--,*" lor use dlA"og ft~. 3 Now poaItlon tlla conlal... benulh ..... arid of the cy\otKIw bIoct<. I t - ,......... lhe drain plug !rom the IrOOI (YZF750R and sP modaIs). Of OlIo. (YZFIOOOR models) of ..... and of The block, and allow Ih. ~oolam to complelely draln rrom lhe ""IIi"" I _ -.mr.tionI) " - - ' on ilia other _ DlIhe t*od<. Retan the <*I - . g .......... lor ....

-"-

4 PosiIlon Tha COI'Ilatner ~Ih ilia coolant rtoservoir. Remova th' rKervoir cap, 111." ........ the ~p and daIKh the hoM!"Om Tha bottom of Tha . - , and allow the ........ aln,ng cooIInl 10 COtI"Ipi lhe rwervoir and secure H with In. clamp. F"rt lhe

....

_.....

22.311 Un.."._ the cylinder """In P/"'It on

22.3b. • and allow the coolant to dnoin

22.4 Ramo .... ilia cap !AI and _ hose (B)

the

Every 16,000 miles or 2 years Flushlrtg 5 Flush the Iystem with clean lap water by w-tJng • ga"Mn I'-. In U.
lhol dr.,n il0ii0(1). II the radiator ia ulJemely comxIed, ~ ~ (eM ChIpIer 3) a'Id ~ .... ~~proI~.

e elMn Ihe drain ~ then instill! the drain plugs using the old _ling wast... 7 Fi ll tha cooling Iys' am with clean water mIxed ~'h 8 flushing compound. Make SUfi the flushing compound I, compatible wllh aluminium compone.n". and 10110101 1M manufactu ...... Instructiona carefully. Inll.lll

1M po:-. cap. S Sian the ......1... and allow II 10 rNCh normal op"nlt"'!! tempwal ....... leI h run for abouI , .... IMWIM. II $I"" .... .-.gone. lAt It cool lor • while, Itwl COM the ptMaft cap WI1h • '-"Y rag ...:I tum II anll-eloek~ to u.. fnl Slop, ~ wry ~ that may 1M pr..n In lhe system, Oneto the hissing stops. push down on !he cap wid ~ h compIeIe/y. 10 DraIn the system once again. 11 Fill tha Ivatam wllh et,an "'a'.... and ,~t IheprocecM.InSt~ 810 to.

-.

"25

(..

14 ....,.... the ~"IIA the WWJ up 10 the lop of the ~or or ... neck). _ the ~ CIP. Now IIIIhI c:ooa.u_1o "'" UPPER ...........rt. ( _ o.ny {pnt-ride} 15 S*,Ihe.-.gone _ _

~toidloofot210

3 minUI". FIi~k lhe throttle lwislgrip part open 3 or 4 I.,.., 10 llIa1 lhe eogioe speed

..... to apprtllUll"WeIy 4000 - 5000 rpm. lhen stop the eogIne. N"J a~ \Tapped In II>e Sy$lem should h.ve blfd back 10 Iha radialor liller

oecIc ~I lhe small ·bore air ~eed hoses 18 LeI lhe trlglne COQI IhOlO remOva Ihe preeeure Caj) . . dMcfIbed In Slep I. Cl>ack INI "'" coolanl ....... it. still up 10 lhe lop of the radlIItor or f k n«k. tI It'a low, add the epIQifiad mixI ..... ""II It .--:t- the top. ReIi1 the~CIIP.

17 Chid< lhe cooiaIll ....... In \he resetVOU" _topupll-V 11 Check lheaysl"" lor INks. IS Do not dlapoH 01 tile old coolant by pourng down the chin. _ po..- Into a heavy plastiC contal ....... up It tightly and lalte It Into an IUlhorlafd disposal ana or a.vHa "Ilion _ _ We rning .1 11>& beginning oll~it. s.ctoo. 20 In.tall Ih' body panels and ..II U required by your model ( _ Chapter 6). ~

~

1 0... a pert.xI of tImOt theW- wIIl\IrdefI or may be wnhed out ot the baeongs by inc::Otr.ct ... of )eI washes. 2 o; ..llIIKl1bla 11>& lI&er1og head tor reo grMSlog of lhe bMrInos. Rei ... 10 Chapter 8 tor delal".

25 Brakes and clutchfh.ud change

. ~

1 The brake end clutch IIuid IhouId be ....0Id ...ery two yea .. or w"-'- • mal« eytind« or eaIop«/ reIeaH cyIondar 0Ya
bINd,,'' ' -~

Refilling 12 Fit new

_ling w.~ onlo the draon pklgoI a'Id bghten them to the tawIy

to ......... U._01_

Wlterlrljjl tlte rysi'.m. When the system appears ll.all, pUn the bikl 011 Its st and and shaka" .-gIltIy to diAipatl the cooIarrt, then placl the bike ' - k on the IIIand and lop the ')'lIlem

1 0... a PIriOd of time ttw grMM .... hardeo and $I will ~a the "-ings.

2 The r_ auapenlK>n COffij)OfIIKlIS ara nol equipped wllh~ ... n,ppIes. Removi Ilia Iwlnllarm and l he Iuspension nnkage .. dUCrlbfd In Chapl ... 6 tor greasillg ot tile

""""

up.

1 The .... WI. dflteriorate _

Every 28,000 miles (42,000 km) or 42 months Ceny our elf rna IMma undw the 4000 miIfI ~.trrll "'-' pU ibIowo'>g

rna

Z1 va/vto clearances check and adjustment 1 The 80\1l1li mull be compIelely coo/lor "'it. maint-.ce ~ .... tat the machinoo lit baIore bagooning. 2 RamoYil lhe valva cov .... ( _ Ckepter 2). Eltch cy\iflderll referred to by. number. They . . runberad 1 10 4 from tanto rIjtII. 3 MMII II ChWt or IkIII;:h 01 .. _ poeItIOnI ~ht

eo IhM a nota of 8Idl cIMrsnce can be made ~ Ihe '"""'-" ........

4 Ramovto tile leh-hand crankshaft end-

co_, secured by Ihree ",.ews, and !he umong ~ plug ( _ lIIu11l"alion). The C-rlngs call be .eused 1/ lhey .. a In 000d con<:Iitlon, oIherwI.. <:!"IKMd lhem. In order to tum the ~ .... a W 18b1e boll and collar must be th ...ded Inlo Iha end ollha crankshaft. Obtain 11>& 'oJquorfd part • •1 "hown In the diagram. thetl fit the collar onto the bolt and ""-' the boIlln1o the cnnks/VItt _ lightWl ~ - MIIoc:Ia gMt.-.d ~ 1hs _ brska to pr ... ent lhe '"'II,na lumiog (see "'lI'1Ition 10.2b In Chapter 21 . A I\ange nut

• period of

U.... and 10M lheti" atIec1",-, Iead,og 10 ltiCky operIIllon or loss. or allowing the ~ of and dirt. Reier 10 Chap'''' 7 (brlkea) or Chapter 2 (dv1ch).-.d dlsmlnlle the componsnta lor Mal raoewal wert two~.

.or

nuod

' . 26

Every 28,000 miles or 42 months

21.~

The

""m.... tt IobH lor NO. 1 cyIIndow 8houId be' tKIrog ,w' Yfrom NCh ou... .. -'>own

!he ........ ~ • the ball . . . to. . _ 1ns\8lld of a collar - tighten the """ IIQIIinSIIhe end 01 the crankaha!! 10 lock tha boll (... UI"ltritlon) The qiM CIII'I I'>OW be Iurned

usang the boll ,"x. l..-ning it In an ....11clockwl.. direction only (.... lIIultratlonl

A.ltem"r .... ly. pl _ Ih' motorcycle on an It.
gnu'Od, IIIIect • ~ ~ ..w;!1OW1 the ... whMI by hoInet In It, normal dnetion 01 '0"1100. II IvaBaDla, Yamaha', 1jl«:11Il tool -ooty, CONIItinQ 01. timing roIor •• belt

not depreqlng the".........:1 _I-.;:Ing _.y from...,1\ 0111«. then Inwrt .......... ~

21.a. Maka ..... 11M".... IobH _ ~!he

C8n1MdIhe ~

Every 28,000 miles or 42 months

and. dowel pin (PI. No. .•US·81873-10 Of :)3M.81673- 10, 81317..(l8(l3O and a:J6(I4. 0lI071) be...-d - fit u.. pin Into !he ~ In II-...-.d oIlhe~. Ihen locate the rotor.,... the pin .,.., light.., \he bolt ( _ IIu • ...uon ' O.~ In Chap! ... 2). the nata on 1M rotor, not !he boll, to tum the engine. S Tum the englnt until the 'T' ""'" aligns willi !he ~ In the inIpooctjorl.mdow 1_ y....".tion) . and 1M c.mshatllat>-. lot the

'*' ....

u..

slight drag when tile you pull the ~ out 1_ .....~. Knot, .... the,.....~ 10 ot>tPI !he u.ac;! <; ..... ance. Record the . . - n d cIsInnoI on the cNr1. 7 Now IUln the 8001,.. .nll~loclr.""'M 180" lhaI1 • l um) 50 IhIII the cutout a/;gr. with the polnt., in Iha Inspection window .. ahown

_ . and the dol on NcI1 camlhoft .'Ign. wllh III. dol on the camshaft ~Id ... (•••

80d the c.nshatt ~ lor the No_ 2 ~ ... 'King .way from NCh 011>10' 1_ ....tmIonl. The No. 2 eyIinder ill now.t roc on IN COmprMSlon Itrok.. MNlUr. IN ~anc:ee 01 In. No. 2 cyIInUer ....... ....-og the m.thod descrlt;,..;Iln $11p 8.

IlIutlrlllonl' II lIMo cam 10_ ar. facing ~ ..::h other 80d the dati do not ~.

e

Nowlunh ..... ~t8O'(NII Ium) .., that tt. 'T' ..-.k 00 tt. roIOr IgIIin

rctaI.the . . . . . i~ 'ww36O"fgneU U'!\I.a Ih8I the T nwI< ~ _ _ with the p..-nl. in the Inspection window The carrlahaft IcbM win now be lacing away from

-.._tt.~~ tt.~...n:Iow

No.1

(Ieft.~~I_.waylrom.::h

Nell other aoo \ha dot. will be . 'Igntod. m.."lng the No 1 cylinder Is .1 TOC (top d.:I 0WItr-l on 11M CCIn'IpN5SIOn IJIrdefl lobe and IoIlow.. 01 MCh varv. and chM:It \hili ~ It 11 firm liking III - )lUll .r.ouId 1M •

•

....:1m. camshsft ~ lor tt. No.• C)tn<* _ IIoClng away from...::h other. The No.• cy1ll1der ia now at TOC on the cornp.-ulon stroke. MNaure the clflflreOCM 01 tN No.• cyIIncMr ....... u.rog tt. meIhod deIo'Iled ~

.....

II Now II.o"n tt...-.gInI WItk:Ioo::I<MM 1110' (hall

all.mj..,lhIIItt.o;:utout-'_!hepoonW as &/!own II\d IN lor the No. 3 ~ . . I.,.;ing --V from I8Ch _ . The No. 3 cylinder" now .TtlCon the~~ ,",-"!he in the 1n1PK11on windOw

~1I1obes

~"'tt.No.3~""""'~tt. rnIIhod .-:.I>ed in St1IIP 8.

"27

10 WhIrl .. ~ Nve ~ ~ ..-.d chIrI..:I, idIwIIify whether the ~ 00 ..., wive ,... autside _ apeafied. If It m.,

the aI*" bill""'" the cam roeo- II\d the varv. ......1bII nopIeoId wiIh OM 01 • ~ whicI1 will ....tore tt. con-ect clearaocfl. 11 $hIrn~t~"""""oIthe ~ t - Chapt. 21 n..r. ill no nMd 10 .....-- IlOIh carr-.t..n. II ...... from only OM . . . 01 thII .-,gine . - ropIacing. "'*raga ewer the spazI< plug holes .wid the cam cl\aln IuIlr* 10 ~I e 811m from drop!)Ing into lhe 6r1gIne on _ a i

12 WIth the camshaft rerncMId. r.nowo IN

cam 10li0,,,... of the ya"'- In question. then

,.rIeYe

IN shim from tN InsicM 01 tN follower 1_ Nlultrallont.l. 1/ It II nol In the folio"' .... pick II oul of lhe top of In. val ... using wiIh

tl'~er

I magr>et. I smsll scre",drlver

s dab 0117_ 00 R (the IhIm wiI atidl

tothllgrwM),CO'a~_.~'"

pliers 1_1IIuatratIon 21.15111 00 not .... the WIim 10 , .. Into the .-.gina 13 A lII.a marie should be stamped on In. upper 1_ 01 the s/"rim - s IhIm mar1<..:1175 ill t .75 mm Ihlck. If the m.n. ia nel visible In. It*T1~wiIINvelObII~.lIiII ~ thai the en,m Is anyway 10 Check IMI It has not

....tratlonI.

,,-r.,;l worn 1_

1

"28

Every 28,000 miles or 42 months

27. 1'" ShIm Mlectlol'l chart- Intake canun.tt

Every 28,000 miles or 42 months

1. Usln\! the 8P!l
0.05 mm incr"", .. nlt "om 1.20 rnrn to 2.40 mm, No! e; It the /'8qulF8d replaClfflHlnt shim Is greIIt&r than 2.40 mm (the 1lIrg
."""abl.,). tile

v.~

Is probably nor sealing

com!CtIy _ to .. build..", ofc.vl>on deposits lind should b$ chM;~~ and c,",,&d or IMUrfaced as requited Chapter 2).

r-

15 Obtain the ,aplaCflmeot shim. then luMeal" It wllh molybd""um disulphldfl and iii ~ Into Its recess In the top of !he ""IV8, with the size markir>g on each shim locing down 1_ illust ration) . Check ItIat the shim Is corM<;l ly _led. Ihen lubricate th .. lollower wUII molybdenum dlaulphide 011 (a greas
50150 mixt",," 01 molybdenum disulphidoe ~f_ and ..-.gone oi~ and Inatall ~ onto the

vatv9 (see lII ... stration)_ Repeat the process

'·29

l or any other velvet! unt~ the clearlll>CeS arl Qorrfl()t, then In.tal l Ihe cam.halts (..... Chapter 2~ 16 Rotate the crankshaft several turns to seat the new shlm("). then check Ihe clearance . . . .0

11 Install all disturbed components In • ....... _ of the remOVllI sequ"""e. Ins\all the t iming Inspection plug and th .. crankshaft end.cover U$ing new O-rings and tighten the

eod-ecvOlf screws to 1M torque setting opecifIed 111 the beginnJng 01 the Chapter (_ Illustration).

Every 60,000 miles (100,000 km) 1 The

28 Alternator bNIhe& -

bru~~

will wear down wnh use and

should be replaced w~h Chap! ... 9 lor details.

renewal

!lew

ones. Reier to

Every four years 1 The hoses will dale
29 Brake and clutch hoses -

should be replaced wfth r'Oew ones ~ two yean regan:flesa 01 their apparent eono:Iitioo. 2 Ral ef to Chapter 7 (brakes) or Chapter 2 (clutch) ar>d disconnect the hose" from the

~.

Non-scheduled maintenance 30 Headlight aim check and adjustment

~ ~I

'"

Not,; An improperly edjusled r-1IigM mil)' c.",." probl!tfrn for orn::omlng traffIC or provide poor. ""safe illumination of the rOMI M»M. 8etOIfI ad;usllng !he '-dIigIl1 aim, be

Sulll 10 consult with Ioclll/raffrc laws and regvllJtions - f<x UK models reler to MOT Tes! et.d<s In !he 1lfIfftn!nce Merion. 1 The head!iQh! beam cao be adjusted both norizontally and EIeIor1o rnakrog ""Y

"""""'fly.

Bdjustment. chock thAt 111.. tyr..

~

.....

correct aod th .. suspenslOf' 11 adjusted as ''''lulred. Mak.. a ny ad justments to Ihe hiladl ighl aim with th .. machine on lev," ground , with the fuel tank half lull and with .. as.lslanl sittinll on tl14l .... al. ~ the blk .. 15 us.uaJIy ridden with a pas.aeoger on thil bao:;k. have a secood assistant to do this. 2

On

YZF750R aOO $P mod .. ls. venfcaJ

adjustmMlt I. made by turn ing Ihe adju.ter screw Of' tll8 top irIner comer of the headlight uoil C.... illustration) Turn It ckx:kwi.e to .aiM \he beam. and . . \i·CIOCkwise 10 lower ~. HortzonlaJ adjustmeM Is made by wmirIg the adjust... !!CNIW on the botlom out ... """"" of tt>e heedlight ....1. Fort"" riQht.hMd light uoit.

master cyllr.:Iers end caliperN$Ia"9 cylloder.

Always raplace the banjO unkJrl .eallng wasllenl wilh . - ones.

'·30 Non-scheduled maintenance

turn it ~ 10 mow. lhe DUm 10 the 1Igm, Ind ~ 10 " - h 10 the WI.. For 1M left·t.Id light unil. 1U'II1I cIockw1se to """'. ttle bum 10 In. rIg~t. ami antidockwlte to move 11 to the left. 3 00 YZ~'OOOR~, vertlt;al .cIJlI$tment S _ by turning the adjust.- kootJ on bottom outer CorIIW 01 Nell _'~t unit 1_ 'II.. SI. anon). Tum It ..,ti-dodc_ 10 ...... 1M beam. and clock_ to 10.... 11. HIlrtzonUII ~ • ....,. by Iurning !hi 1Id;.oII _ _ en !he bonom ...... "."... d

tne

"",t.

INCh headlight I.....,~

right-hand beam. tum It clock", ... 10 move the bNm 10 the let!, and Inll·"lockwlselo

_.::eMS

It 10 the f\oIlI. Remo'4 the tor to the

~

I~

~

....

(_

"-" 31 Cylinder compression ,hod<

t AIn<>ng

other

thing. .

"'11'''''

a Ipark

~u\l

w'lJf\Ch. A

COfnpres"on lIaUQ8 with. th'H()ed eod for the spark plug hole II preferable 10 the type which '..:tlll'M hand ~ to mamtaln a tighI . . .. DependIng on the 0VI<;0me of the inltoaol *t. • aquW1.type oil can .... y tis<> be

."'ake 3

....

the

---

01

this Chapter 10<

c:ompre.ion /igI.o'_.

w......

cJewwoc.. we

...

4 Atr. • short wNIe 0II1houId begir1 to NIP out from the od gallery ~ug. If no 011 h..

appear«t ah ... one mlnut•. atop tile enll~ _~. "tile 011 00. ~ '«*" afl .... h.ortt. rninutto. ~ the po--.. r.guIator II atuck open. !tie oil pump III faulty, the 011 .UU- 01 fill ... " blocked. Of thare is other 5

1 None of tile

~

CO'Veted In rtIiI ..........

Sf' linedlight.withonlyanan011allpresaure IWUch and _.....,.. ..,.;I light w~

1_ Chapt ... II lOt !unh .... In/ormation). II a IubfIcIItlon ~ is suSj*;t«t, tQI ched< theoll ..... ~£Wy~~ 2 II tile 011 ........ eoon of tile . . . . . . . ~ 1"t'II..... 3 To ched< tile oH pressure on VZF750R and Sf' models. !'a'TOCMI tile rignt-hend /alring ekIe

P<><><

I*fotmanca may be c;auHCI by '-king w........ IncotreC1 _ dMr_•• ~ wom pistone.. rlnos indio< ~_. A cyIirmr ~ chedc ..... 11 I*p pinpoint , ' - conc;hho,.. and can 1'-0 indicate the pteMfICe of el
and

at the beginning

~

YZF750R a nd SP models

lINd gaskill. or

~ug.

- tIlent is no need to ...,...,.... " 1_ ~I StIIM the ...... ...:l slow It 10

USIl\II I .c.-.wd,....,.

lrom below '''''' M6cIlight ( _ 111"I"allon) For tIM t.\t-1'Iand bMm. tum 11 clockwise 10 move \he ~ to the right. anc:I Inti-clock'oYlM 10 move II to the Itofl. For the

meMo

COI'I'ltCtly Nt 1_ s.ction 21) ..,.;I rn.t the cyIindIr ' - I nuts . . tig/lt«Ied to the corNCt t~"""'11 (Me CNpt_ 2). 4 Re! ... to F.."I Finding Eq<;lpmenl In lhe R.!.... nc. ...:1100 lor d.talll 01 tile _ _ Rei_ to tile apeeI1icatklnl

panel ~ Chapter 8). SIacI<.., the 011 gtl1*y DOlt ... the r'oghI-/I8nd sicIe 01 tile cylinder IIMd

~ ~ by

Checl
.~...:l regulatOt, u.. the 01 pump ~ Chapter 2). If no problems er. found wtth _ items. ~....."WlllboIltIaIlt1e~oII el •• rances If. .xellSlv, and tile enliine

~to""~1ed

_.....

, 111he 011 appn ... v«y quicJ<jy and apun, out. the prasaure lTIIy boa too high. an .. ~ II clogged, the J1tgUIalOl lac 'tuck cIoaed Of tile wrong or-Ie 01 oil ..

""""'''II

""*"

--

7 Tlgoht", tIM oil gtllllr)' bolt to the tOlqlll _""II apecltled .1 the begtnnlflll 01 the

YZF1000R mod.l.

a To check tile oH pr'''Il'' on YZFtOOOR mod.ls, f~ the klw..- fairlno ( _ Clulpl..- 8). A sultabla gs"", snd aoeptw p;.ce (wI"8ch IICfews Into the CHnI<ea.) ... be n-dod. Vam ..... prQ¥ide a kit (Pt. Noa. 90890-03153 and $OUO-03139) 10< thII

.."... II Warm thllIfIQIl'II up 10 ........... -"'1In!I ~1Ln

u.. lIop~.

10 F'IIcto. IU!taDIII contaw-t>*>w tile rrIIIin ~ plug. whictt 1It>*>w the ClDIIIuhaft end·cover on tlul rlghl.hand lid, 01 In. 1fIIIitw, 10 ClItch lIlY 0111_ lI\o4lr1ttion) 11 Unscrew tl>e plug and IwI!1ly screw tl>e ..s.pI_ Into the ~ Connect the gauge 10 tile II oil .. lost, r.pIInbh II to 1M COtfICt ........ befOtI

011

ttor_

ad""....

~(.-£Wy""""~).

Non-scheduled maintenance 12 Star! the engine and 1r.crea5e t~ engine speed to 4000 rpm whilst watching !he gauge reading. The 011 P'fiSIK9 should be ,.mUar 10 that given In !he Spocifocations at the start 01 thisChapt.... 13 Slop tile engIne and II"""~W Ihe gauge aod adapt .... Imm the crankcase. Instailihe main oil gallery plug using a new .... allng

washer. and tighten

~

Cl>ec~

the 011 l.. v,,1 (SH o.Uy (pre-ride) CMc/rs). If the pressure 15 signifICantly lower Ihan the standard, ellh .... the pressure regulator Is S!I>eI< open. the oil pump is faulty, the 011 strainer Of filt. is bIocklld. 01 !here Is other engin8 d"""'llO. 15 Begln diagnosis by chocking the oiIlilter. strainer and regulator. then the oil pump (_ pro~ .. ms are found wilh may waU be that the bearing oil

Chapter 2). II no those ~errt!I.

~

33 Fuel hoses renewal

to Ihe torque seiling

specified at the beginning of the Chaplet.

14

1.31

light may be laully. Check Ih"'" and the circuit and repla~ wilh a new one if necessary (see Chapt.... 9).

clearances are axc"".iv8 and the engine .--;Js to be overIIauIod. II the pressure is too

high. ellh .... an 011 passage I. c logged, Ih .. regulator Is SUlck closed or the wrong grade

01 oil is b
AI/models 111 Rele, 10 Chapte, 2 and rectify any ~ befOferI I~ oil HIVI' sen""" or ilS warning

Wamln,,: Patrol (9"sollne, Is e.,/reme/y flamm.b le. so t"ke ertnt preceu/ions wh_ you worlr on ..,y part of tile fuel .syst..... 00tI't smoke or alk>w open flam es or bare lig!>1 bulbs neal' the work a"",. lInd don't work In a fI/JI'/JfIII where a tlaWrai gn.!ype -w/iance Is pnJSenl. " you spill any fuel on your sJcln, rin se II off Immedl.tely wllh soap and ....,.... WII_ you perform any kind 01 work on the fuel system. _ ..fely gJassulUld h.". e nr. extinguisher sult.bIe for • CI.ss B!ype'-"" (rIamm.b/e liquids) on hllrrd.

A , •

1 The ruer deliwry hosea !Ihould be ~

alt.... a few Y""'" "'!II'rdless 01 their cood~ion. 2 Aemove the fuel tank (...... Chapter 4). Disconnect I~ fuel hoses lrom t~ luel tap. fiker. ruer pump and from the cart>urettors as required by your rnodtN. noting !he routiOlg 01 each h08e and where it connects (see Chapter 4 II required). k is IKMsabie to make a sketch 01 the various hose$ before removing

32.10 Main 011 gellery plug (am>wed)-

YZF1000R models lhem to ensure they we correctty Installed. 3 s..cura Bach new hose to lIS unions using new ctsmps. Aun the en"ine and check for leaks before taking the m achine out on t~

""".

34 Front forks oil change 1 Fork oH degrades over a period 01 timtt and loses ilS damp;ng <jUII1~1es. ReIer to Chapter 6 lor front fori< removal. 011draining and refilling. IQlk)wing the relevant SI&pa. The lorks do not ne«I to be completely d~.

1

2"

Chapter 2 Engine, clutch and transmission Contents AiI.".lor drive shaft. starter ckl!ch lOcI kllelr.cfuclion gear - .......,.,.aI, ~ and InsUillation . ..32 AII .....,Of~frecIifW·....-.IIOd....- .. _ CNpt.- 9 c....<:hI*I-'~~-....-..' ~_

inItaIIeIIon

••• 25 ....-aI. ~ a'Id ~.. c.n..n.1Od IoIIowtn - NmOYIII. ~ IOd _ . 10 CIutch- bIMdO'og • . 19 Clutch - checI< • • • .-~ .. 1 CMch Inspection III'Id Installation • • •••••••• 17 Ckltcl\ _ mecharlism oYMhIIullllld ....\alIation ••• 1B ConnectIng _ - _ai, k'IIj:Iectlon _ lnahllation .......... 27 c...n..chow. -Inspection -..w:in9 .................. 2' C
c.n "'*' tenIionIr .-.d ~ -

_al.

~ ....:I

--....

"

_al.

m'" t.e.ingII-....-.I.

IrWtWllatat1·"" aft., ov.mauI .

01_-_

Picl<;·"",coiI-..bIy - NmOYIII..-.d In$lall.lllion PboIOtl r'i'>gs -1nIpectlon IOd InIw.tIon

.. 28

f\uooo

Sper1<;1*'II1Il'P-gI..clI...cI~1

_..., """

-".,.." .

.. 16 15

..

.... 3-t

..

.-cto.pI., Mod

~

.. _

. . 32 Chapt. II

T'''''"''''asionWII. -~.lnspectlOll...cl~

Tfllnsmosaion ilia!!, - femovaI aod Installation. VaIwI ~.....,.. - ch«:k ...cIIldjUS\fT&11 • V...... <;CJWI- ......,.... lind InIt.a.tion V~~gukIea--w:ing.

... 30

29 • . _ Chapt... I 8

.12

2

Genet"al

Comp'MIion ,.,10 C)"'oWIdIf I"U"PlbwIng

Chapter 5

5eIecIor dnJTI n;l1orks -1'II1"I1O'Y8I, ~ II1d Im\akttQn .... 31 SIartef cIuIch Mod ~ go!&" _......,..... Instaaat;on . Start. motor - l"IIITIOYallInd Installa60n

Specifications - YZF750R and SP s....

.. _

.oded,.,..,.;ng,..... pro<::«Iure

Degrees of difficulty

...

.-Dllyt--tldeJdMc:b

Oil ~-ct-.dt . .-CMpIef 1 011 pump - _ . inIpIction ItId InltaIlIItion • 21 OiIamp.oiIw.m.r_~noIief ......... -_,~ and installation • ..22 Openotions ~ witt> u.. ...... 1n lhetmm. 2 Operations f9QOJIr\'Ig engine ........... . 3 ~_.....,...,inIpIction....:l_

np.;tIon rd

~ bIo!:k - ~ ~ and Nt3Ia!Jon • .1 4 C)firIdIr " - ' Mel ..... -~. inIpection a'ld ~. . ..................... 13 Cylinder "-eocI< . . ............... _ CNpw 1 EngIne - removal _ IMtIIIlalion . 5 ~ mechIInIsm - 'emovai, inspection Mel Insldation •••• 20 ~ Information . Idle ..,..0 - chick rod ~ .... _ CI'IIpI.- 1

'''' "-'"

.33

Main 8IId coonectlng rod beIIrlngs - ~ ilIonnebOrl .••...... 26 • • NouInII swtIch - cNc:k, NmCMlllIIr'od Inst.oIIdlon . _ CIwpw 9 01_ Nt ... - c:Mngot . - Chept. 1 01 cooief - NmCIYIII _ .......bon • 1

IMP engine NIlM - general Wotmation

F"............ ln-hlout 1411cc

72.0m:n 46.0 mm

---

11.510 1 1 t041romiel!1OrIg/11

Wet~. sa·~

0-

oDnItant _

2- 2 Engine, clutc h 8Ild transmission Camshafts Intake lobe heigh!

""""'.

32.601032.10""" 32.50 """

s.Mce limit (min) . EmItuII lobe helghl

-........ s_.

33.00 10 33.10 mm

s.Mce limit (min) . JoumII

<*meI.-. . ........... .

32.90"""

24.43710 24.450 """

~1_4 ~2_3.

24.4701024.491 """ 2ol..5OOI024.5.2lmm

~1..-.:l4.

0.020 to 0.054 """ 0.050 10 0.08( """ O.03mm

-.....

............

~2..-.:l3.

Cylinder head W~(InIu)

•

0.03 """

&_-

Valves, guides and springs

.........

v.... ~.

"""'" .

---, 4.47510 4.490 ...... 4.«5"""

Sr.4oe 1m! {1I'Wl} • bore d~ 51anciatd . s.Mce Wmit (max) •

Gukje

-.... -. .............. .......-

4.500104.512mm 4.550"""

$I ..... lo-guicM~

s_.

0.010100.037 """ 0.011"""

s-IoIlWnIt (rnPl •

22.910 231 mm 1.• 9 10 2.48 mm

F~_

0.11101.1 """ 0.11100.11"""

.....

v.... i!t. "..., Slem diameter 51-*
s..w:.

----"""'" """'" s.Mce1imil(mu)

7.55107.75"""

. ............................. .

4 .• 60104.475""" 4.430"""

s-IoIlmit (mu) .

HeId<*met.- . F_width SNI width .•

"...

Margirlth~.

~ v.... awn nn>Ut (rnPl

..... .....

0.025 10 0.052 mm 0.10"""

24"1024.6""" 1.76102.76""" 0.9101.1 """ 0.85 10 1.15 nvn 7.95106.15nvn 0.01"""

V. . . ~_1fIngtII

..... ...

71.98 10 72.02 rnm 0.03"""

'---.

."'~ -"-'

.,.. ,.

VIM ~ bend (mu)

1.r""" 1.9 ......

Cylinder block

W~(mu)

. IMIity taut-ol""""'""l (mu)

'--

."'~

Engine, clutch and transmission 2- 3 Pistons Pilton dIImet. ~ 3.5 rrwn up !rum skirt. .t 90" 10 I*IOt'I

... """.

11.90 10 11.94 rrwn

Plston·to-DOnI c:Iearance

""""".

~"""(ma>C) .. PislOO pin di""""• . PistOl' pin bani in pialoo PistOl' pin.lo--plstoo pin DOnI ~

eli"""".

..s.vto.lmt.

...... --. ""'.... -. ... ...-

0.07 10 0.09 rrwn 0.11 ...., 18.9911019.000 rrwn 19.004 10 19.015 rrwn 0.004 10 0.024 ....,

O.oro .....

Piston ring s

'®"

,,",100 rlng-Io-groove cIeet,rICfI •

2.8 ..... 0.8mm 0.2100.4""" 0.03100.01 ....,

Ring ...cIgoop fir-->

0.2 100.4 mm

-

RIng ...cI gap (nslalled)

Piston mg-\O-9"'I)OIIe~

CO . .

SlcM-I'lIiI...cI gap (hstaIIotd)

2.8 llYn ,.~

0.021<>0.06...., ,,~

1.5mm 0.2 I<> 0.1 rrwn

Clutch

--... --. """"". _.........Fi1cItOO plat..

""""",.

""""". tn** . s.vQ h i

2.9103.1...., 2.8....,

""""",.

WIIrJ)e(I8(mul .

",,"'

S""'""'.

s.Mc. limit \min) . Puahrod runaul (mul •

..... ....

1.&102.1 ...., 0.1 rrwn

,,~ ,,~

O.S"""

Lubrication system

"'R-.. ........ "'

CIJ**Ig pr1IQIQ •

........ ""orl~to-OUI. rotor ~. .

o.rt. rotor·to-body ~ Connecting rods B9-«'od tide <:iNnonoII . B9-«'od 011 cIerarIce .

-

_ChIpI.l

69.69 I<> 81.01

'* (4.81 10 S.60 a..,

0.09 I<> 0.15 mm O.03io 0.08 mm 0.160 10 0.26.2 rrwn 0.032 10 o.ose rrwn

Crankshaft and bearings M.-.~01~

......

0.040 I<> O.(l6oI rrwn O.03mm

Transmission

-""'-

YlF750R

""""'_.

Gew I'1Ilm (no. of teeth)

,"-

"'_.

1.8961<>1 (9114f1T) 2.6881<> 1 (431115Tj 2.511 I<> 1 (36/UT) 1.lMlio 1 p:lI"tTT) 1.556 I<> 1 (28f18T)

2

2- 4 Enginu, clutch and transmission Transmission (continued)

....

'YZF75OR (conUnuod) 4th II"'" . 5th II"'" .

,

Shalt Nnou\ (rnu,\ Gear ralias (no. 01 teeth) Prlmwy reduction . F"f"I8J reduction

l atgear . 2nd;ear . 3rd 11""'. 4!h gear

.

",,...

6!h II"'" .

Shalt runout (maxi

1.366101 (2tII191) 1.217 to 1 (28123l) 1.083 to I (26I24l) O.06mm

1.896 to 1 (9 1/481) 2.438 to I (39116l) 2.462 to I (32113l) 1.941 to I (33,I1TT) 1.63210 I (31119l) 1.435101 (33I23T) 1.300 10 I (26I2OT) 1.190101(251211) 0.06 mm

Selector drum and forks Selector fork shalt runout (max) .

0.1 mm

Specifications - YZF1000R General

'''' ""- .

'>'-""" .

Stfoi<e.

Compression ratio

Coofino;Isystem .

Clutch ..

TrDIIIIIT1ission .

F ..... drIv1I.

Four·stmka in-liM lour

""'~

75.5mm 56.0mm 11.5to I

1 to 4 lrcm left 10 righl Uquid COCII8d Wet multI-plate Flve-speed constanl mesh

eN.

Camshafts tntake toto. height Standard .

Serv\olI timit 1min) . Exhaust toto. heighl

S""'"' . Service 1lrri! (min) . Joumal~l er.

32.50 10 32.60 rrvn 32.40 .,....., 32.951033.05 mm 32.85 rrrn 24.437 to 24.450 mm

I-ioIderdiame!er CylInders I IUId 4 . CylInders 2 IUId 3 • Joumat oil cIear~ C)'Iinders 1 and 4 . C)'Ilnders 2 end 3 FIunout (max)

24.4701024.49 1 mm 24.500 10 24.521 mm 0 .020100_054 mm 0.050 to 0.084 mm 0 .03 mm

Cylinder head warpage (max) •

O.IOmm

Valves, guides and springs v..... cI6aranceI . Stem diameter Standard . Service _ (min) .

4_475 to 4 .490 mm 4.445mm

Guide bore diameler

S'""""" .

4.500 10 4.512 mm 4.550mm

Standard . Servk:elimit (max) .

0.010 to 0.037 mm O.08mm

ServIce limit (max) . Slem-to..guide cIear~

Engine, clutch and transmission 2-5 Head diameter ,~­

SMtwidth . Marginlhickness . Valvtolift .

""-,-

Stemdiameter Standard . S8rW;.

~..vt

(min) _

23.41023.6 mm 1.63t02.90mm 0.910 1.1 rrffl 0.45 10 0.9~ mm 7.4S 10 7.65 mm 4.460 10 4.475 mm 4.430 rrm

Gukltl bore diameter Siandard _

ServIce i..vt (max) . Stem-to-guide cItIarance Stand;rd .. Senrice limit (mao<) . Headdiamet ..... Face width

Seal width . Margin thicl
Valve stem I'IJI'IOU1 (max) •. Valve s.poirogs IrfI8leogth

Intake _ Exhaust.

-.

Valve spr1ng band lmax) .

4.500 to 4.S12 mm 4.550mm

0.025100.052 mm O.I O mm 24.9 to 25 .1 rrffl 1.63 10 2.90 rMl 0.9101.lmm 0.75 to I ,25 mm 1.75 107 ,95mm 0.01 mm 40.73....." 44.01 mm 1.7mm

Cylinder block 7M ,0010 75 ,505

warpage (max) • OvaIity (OUl-oI-roundj (rna>.) •

O.03mm 0,05 rrm

Taper (max) . OytOndor compression .

0 05 rrm

nvn

_ChaIlter l

Pistons PIsIon diameter (measured 3.0 mrn up !rom skirt. at 90" to piston 75.425 10 1S.440 mm

pklaxisj.

Piston-to-bore cIeanInc
ServIce Amtt (max) . Piston pin diameter . Piston pin bore diamet .... In piston . Piston pln-ta-plslon pin bore dearanc:
0.06 100,08 mm O.lmm 18.991 10 19.(X)O mm 19.004 10 19.015 mm 0.004 10 0.024 mm 0.070mm

2

Piston rings Top ring

,.,,-

Ring eOO gap (Installed)

2,8 mm O,8mm 0.310 O.S....."

Piston ring-Io-groovtl cIeInnca

0.1)3 10 0.07 rrm

RIng width .

''''RIng"""width •

..

2.B ....."

Rlngl~

O.Bmm

Ring w>d II8P ["",tailed) Pislon rtng-Io-groove """"""'" .

0.3100 ,Smm 0.02 to 0,06 rom

Ring width .•

2.5rrm I.Smm 0.2 100.B mm

"'

Ring IhickrJ8SS Sidto-rall w>d II8P (Installed)

Clutch Fricllon pIat_ Ouan~ty .

"""'"" ServIce

Standard •.

IlmH (min) .

2.9103.1 mm 2,8 mm

2-6 Engine, clutch and transmission Clutch (continued) Plain plat.

-~.

Thk:kMM . W"'P"II'I(n"'-"i •.

1.9 to 2.' mm O.lmm

"""'''''''''

Quantity •. Spring free IeogIh Stan:::tard . SeMc:e Iim~ (min) . Pushrod runout ("""') .

Lubrication system Qjj pt!lSllUrll.

_Chapter'

Ro>leI va .... ft oparWng pressur1I • Oil p<.mp tnner rotor t;p...to-outer ro!o< ~ • Outer ro!o<.to-DOay clMrarlCtl .

52.63 to 65.43 pSI (3.6310 4.51 Bar) 0.09 to 0.15 mm 0.03 to 0.0Il mm

Connecting rods Big·end side cI!IIV&I'IeII . Big·end oil c~ .

0.160 to 0.262 mm

0.= to 0.0/i6 mm

Crankshaft and bearings Mein bearing oil c:\oNtnInce . Rur"lOUt (max)

O.tI2O to 0.044 mm O.03mm

Transmission Gear ratIOS (no. of teeth) P!"imar'\I rooduction . FioBI reduction 11tQftlll".

~-.

3rd gear •. 4tll g.ow. 5th gear. Sllallll.lOOOJt (mp:)

1.&59 to 1 (68141 T) 2.706 to 1 (461171) 2.571 to 1 (36f14T) 1.778 to 1 (32I18T) 1.381 to 1 (29/21T) 1.174101 (21123n 1.037 to 1 (281271) O.08mm

Selector drum and forks Selector fork sIIafI rvnoul (max) .

O.lmm

Torque wrench settings - all models Enol"" mounUog bolts VZF750R and SP rnodtIs LOw ... .-- mounting boll nut Upper .-- mounting boll nut .....• • • . . . . . . . . . . . . . • . . . • . Upper.-- mounting bolt pinchbolts .

Front mounliog bolts . RlghH'and front rnountIng bolt plnchbolts • VZFl000A moOeIs LOwer rear mountino bolt nv1 • Upper rear R'IOOJ
Oil cooler bolt .

56 Nm 56 Nm 15 Nm 40 Nm 22 Nm

50 Nm 50 Nom 22 Nm 40 Nm

22 Nm 63 Nm

VaMtcov..-boIts

10Nm

Cam chain Iensiorw" mounting bolts . Cam chain If!nSioner cap bolt . erankshllll end-<:O\l$'" SCJews . • . Cam chain top gukte bolts . CDmshaIl case oil pipe bolts CDmshaIl case bolt, CDmshaIlIloldet bolt,

10 Nm 20 NIT! 7 Nm 10 Nom 10 Nm 10 Nm

YZF750R and SP models Aft. outer bolts on ftXIw.tst hoIderII (_text) . Nloltw"boIts .

e Nm 10Nm

YZFl000RmodeIs .

tONm

Engine, clutch and transmission 2- 7

,,----...

,,"Nm

'""""""-

,,-

01 ' - ~ bolts {YZF75OR) 01 pipe ~ bolts (YZFl OOOA) 01 pipe damp bolt (YZFIOIXlA) Coolant III,IIIeI .......", 10 C)'1Inder head bolt. CooIIInt Inlet lIIIIon 10 cytinder bIocIc bolt •. Clutch rr.n C1u!ch aprIng bolts . Clutch _ bolts

roNm

IONm IONm IONm

"Nm .Nm

VZF75OF1.->1f sP rnodeII • Y2flOOOR models Ck.r1d! m.t« cyIindw ct.mp bolts Y2F1!!oOA .->If SP rnodeII Y2ftOOOR ....... Ck.r1d! ' - brfo bolts Y2F1SOR .->If sP models . YZF1000A moOeII C1u!ch ..... cYJnder mou:lIlng bolts

"Nm "'Nm 10Nm

C1u!dI ....... ~ t-.:l valve . Stopptlf 111m ..., ..".".. ~ bolts 01 PImP ~ 8CfeW 01 PImP mounllng bolts .

"'"'

ONm

,,,,,10Nm

. . ...... .....

,,"Nm ,,-

Oil beI'n. pilla bolts .

OiIlIPf8)'pipe-. . OiIsumptlOlta

VZF1'5OR _ sP modeb YZFlOOQR models . er.n~ i "..." bolts . ~8"""'boIts . ~8"..."boIts . s-'o"Ig ....... ~..:NWS

10Nm 12Nm

"Nm 2. Nm

"Nm ,,"Nm ,,-

OI_~boII

c.n dIM"Il_ til.- bolts CoronIc!Ing nxI <3f> ro,ftS ~-...g{_Tut)

.

roNm "Nm

F.... Nttng • ~or

dnJm ,..,. ..... bolt . Start. clutch bolts . Hy·VO chain gukIoo bolts .

tONm 25Nm 10Nm 10Nm

Af1emalor"""" ntt ~ ,.,... bolts

Pow.- from the ctankII>afl II rout..! 10 the vii the clu1ch. The clutch II of the _.1TUtI-pIaI1 typa .-.d II ge«~ of! the cranQheh. The lranamlssion i• • aj •• ~ (750 modals) or Itv.speed (1000 models) ~tanI·"""'....ot. FlneI """"to the rear wheal II by cham and oprockels.

t.......-..on

The englneltr.nsml""ion un~ '- • IlQuldcooIad In-linol four cyt_ wilh flVfl per cyll,.,.,.,.. The valves are opereted by doubj. ov.maad cemahafts which .... chain drlva1Nioo -m:.Iy II oonstruct«Ifrom ~ ..ay. Tha~ II dMded horizontaI1'f The ct.,kcaM ircorpof"al" a _ aump.

va""

~t.d

IutJrIc:alo::o: system wI\och _ .

~-driYen.

duaI·rotor oil pump. an 011 fill. _by·pau ..... -..bIy •• rIIIiaI ....... .->If aro 011 laval switch. The pump I. d ......... by I 0 - on the back of the clulch houIIing. The 01 " cooled by I cooler wtllch I. led 011 Ihl engine oooIng syslam. A Hy-Vo ch.ln .... nning olllha crlnkahaft

drIvw • tnaft which has the lltemator on Its t.ft·1Iand I<1d Ilnd the .Iart. c:lU!(:h on it. rIghI..-.cI WId.

-------"'-.-

2

Pic:Ic-up a>I.-nb)I (yNt.-and~

0/1 sump. oilst"""'lII(Joil--...

Slar\8I"molor

Wslwp<Jmp

The c:omp<>l*'l1 and ~ listed baIow can be removed wItI>out hiving 10 '-OVfl lhe anglMlt,.nsmI5sIon ',,-"Illy Irom the Ira'na. H~ .• rKIrTIbo.- o! ......

,-"""""'"

requore anenuon at the lime time. !he englroe II racommanded.

removar 01

<><-~ bIocJI. p/aIorIIlr>d piston rw"I\:II

""'"

........

~ .. necessary 10 IWTIOYI the IfIgIIW11ansm, •• ,on assembly "om lila I........ to _ . to !he torlowing c:omponent8. T~d>aftr

S_ _

s-:ror '*"'" and Iot1a

c-... _ _

~""'and-'"

Ifi''''

2- 8 Engine, clutch and transmission can bIo . . - ..... by ..-.g \he tnIIdwIoe to I _SbIa ""DI'kIog IMoghI on WI hyd,lUIl!; rlmp or. su~abIa platform. Maka ..... the n'ICIIOfI;:yCIt it ..,.... _ will not toppIa O'W.-

(.- SacIIOn 10fT".. and WorlmtJop 1pI W'I I"- Ratwance a.acto:InI. When d.-corv>ac""" ..-.y Wiring, cabIaa lind " ' - . II .. . , . . . . . to

1 ~ iI not -.y. eMy to del ....... _ or W ." .-.g.... -"ouId bIo c:ompIeIlily ......nauIed.

-

• • ........,.0I 111C1Otsm.lSlt.COI"IIidered. 2 High mileage la not .necessarlly .n N\dlcatlon trial an o-moul IS .-.:led. wtllie low mll. .~, on Ilia Oilier hand, don nOi precluo. 1"-1"4«1 lor an 0V
...... otIw 11IQUnd~.'" moal "kely g/W ""roy ....,.. of rellabW ~.

ec:.-.aty, a

~Ied ...... or .... MIIdI ' - not ~ run In """*'Y, ~ requIN .... ~..-y~in~~

3 E.o"""'1

_.

and

.>oeeseiva

011

oorwumptIOn ... both Indic8liorlIItIat l"IIon

v.'",

ring. and/or gvidal .... In _ 01 I nenllon. although ....,.. ...... !hat tho! fault iI not dIJe to 01 . . . . .. 4 H the . . . . . II making obYioI.IS knockIog or ~""" the COtVIICbng tods and/or main probably at fault. S LOll 01 pow." tOugh running ... xoasslv, """- train noise and hIgh fuel COI"I!IIlmptlon "'I" may "110 pomt to Ihe _ for an ~.eapacIaltyWItlay ... aIl~at the _ tmII. WI compIet, tuoe-up do. not ~ the afluat;on, 1'l'II/OI" rr.:tIanic:lll work

noI_. beIrirIQI.,

iliha only 1IOIudon.

' M

angtne ovarnaul g&I"IfIf1Il1y ~ _tonng Ilia Inllfflli parts to the .".cor_110M 01 • new angina. The plalDn fInga...cl mIIIn...cl ~ rod ~ ........... IIy,~ wilh """" " ' - and the ~ WIll _ or, Wna.cessary. rIIbor.:!, dl.ring. major~. Gen..IIy!tle v...... _ta ... "'ground. linea !hey ... usually In leu I",," parIect cooeMion . t 111 ", poIn!. The end ..ull1I>ou1d Da • IOIe .. MW ""!Ilnethat wII ;lva . . m .... y I,oub ~f,... miles ., lha

""....

7 Batora baglnning Iha .-.gu>a ovarhauI • ..ad I:tIrougn lh1 Nlated proceduras to larnitlariN w,th I"- tICOpe and _ _ ,. of

)'OUfMI1

\he Iob_ ~ an ...... not .. ilia! dIt'I'Ic:IA but It iI ""- oorwuming. PII<\ on \tie

l'I"IIfIIorlaQ 1I-..n"I~to""""'tt.y

2 ~the..-.gonelldlrty.~WoundI1a mount~, waah ~ !ho
-

beleN tlll'110!1

a ny mljor dlomlniling woO<. TIll. wIll maka

......,.-k ml'Ch _ _ and

ruIo out

~

poII/bUlty

01 Clkad·on IlImpo: 01 din lalling InlO IOITII

mol~1e tMIng lied up for • """.",um 01 two weeki. Check on \tie avaiIabMy of f*b, and maI<..... 1""1 any oaceu.y apaocIII 100II. ~ lind IUPI>IiM •• obtIwIed .,

.......

'M"-I WOtI< c.an bIo dona WIth tYPlC'I WOtkthop hand Mhough • numbat- of ~1lIOII ITIIIWnng loot, .... raqUll"ed lor inIpactIrIg f*b, 10 ~ 11 tt.y fTlUSl bIo _ a d . Ott... I dn~ WIll hlndle Ilia InSlMCtlon 01 parts and oil.,. ad\rICI c:ooo;...,lng NCOI"Iditronlng and 'eplacemenl "- , oan«l1 rule. tima II IhI po\rrIary coal 01 ., ov.rIIauIao ~ ""- not pay to . .tali wom

I""".

-

or"'MIIII'dIrd~.

" "-. float not" 10 ........... maximum lila 8rld minimum troubltl 'rom a ,&buIll "'!II ..... ~lI'O.IIIbIo-mladWlthCll'lIn.

-"""""""'-

IHd t_ ~t'" 9). Alao dlsconntc;1 tile w'oing connector joining ~ l'\1(li1,,", ..... 10 ilia "'!IaU", lead t.... Illustr.lIon) Feed Iha laid It.ough \0 Iha eng"",. noting lIS fOOtIng. 8rld col ~ on !tie CtSr1kc.a ... ID that " doe. not ~ ang;r.. fImCMII. 7 Ramova \tie eartu'atlors
l!195-on YZF7SOR mocMia and VZ1'I000A ~

'"

R emovel

ChIpi.')

, DIIc:cnIact \tie neg.atMI t-Ya) ~ from the beltw)". then d<sconoecl tha ~lllva t..,.)

'-110m ilia IntaI
Clllflorl: The angm. II .....,.. "".,.. ErtQitta _~., ...0 Im/.,lalk>n Ihould ba canlad
-

4 ~I"-1uaI_(Naa.pt.,.4) , o."n Ilia angina oit and Ille COOlant t_

modeI8 ...0-- detach llle vacuum '-'<1-011

5 Engine removal and installatiort

....

:I Remov, tha ...1, _ cover1I or ...1 cowWIg. Iowar faring, 1"""'!I1Iidoo ~_ l&nl!j (Ma Chapt.- 8). Nota: 1111 ~ CMI atayon Iha~ Ihooghit.is _ 1 O _ 1 f . . 1/ could ~I kI tha way and COUld ba a..n.g.d-lIlf1not-. itCll"l~doa/thafl

lham ~. or _ ~ on a.ch aide _

Ilia hoa. from '''''' COiIIham wound ItIa manIfold. t_ 11I".trallonj. On YZFIOOOA ~., ,," Ille ..... y .....,bIy from ". mount, than UIWDfIW \he I!iogIe bolt --.mg Ilia ivai pump and fill.. hold ... and ......ova lhem ..,th U- ' - (III MI...tnoIlonI) , Mlk. I or .ketc~ of .11 Ih. coolIng 'yillm ~_ betWMn th .. 'adlator Ind Ina angl .... Datach th .. overflow IlOsa to Ille ,.......ow /fom Ita union Ju" below Ille ~fI ClIp On ,,'" ,adlalor !in., neck Ramo ... Ilia 'adiator t_ Chapl. 3). but dlllCh IhI hoMS from thai, uruont on the WIg"" componanta taU- than ftOm the

not.

-'f' -. I ' " I • . ,II.~., •. '.

•i

l~gg,~ ;~ g ~i 1-_.~~I~ ~2 ~~ i!. ~

~


I" ~ 'I · "·-!· · IOIII ~~

1~n , - 1,· e_ "", g _ ~ •• ~ 5i~6.i

~i ~. g,.ii

.. ' •.•. "

I'~'I i' ~ ,1 .,-,. '--. ·I~:: II~:' ",i"!!if

3""f:~

;'1: .; ~ is. 2: ••• - " ..

~l~=~~_i.~~f

0

~8.~

•.

B·, ~ 515S·,iS'8.1

0

_~Oi·

,

" .'-

.i·"'''·f~· .f,I·~. j ~,g! r.-Hp ,,-. "

.11·.t.II" IJ._ IIg ~ g~S ~ !!! .. ~-l

1,1"-(1.11•• 1 1l .6 s 0.",

:.t

~:~~' ;~:~~ ~&~Qll. i~§~

.,!'O.,'i~~3 ~i~Ql

G~~&

,~~i&~ •• .!, 3~fl ".'

~ ~

~-f •• ~ I a~ 3

..." ~

&"i

it,

~i

"J'" >i!~ ~~~!!~~i~ .:~!&g~~i;!~ i!~i i-· r~ .j .,"~III.· I -E·_ 11 ".<-["1 '.- .lo',~ I. 'i'. d'·' .', IQ"h,' 2,1

"i"'i"~ i,,;I!"IR

j~'S·I · ' · 9.'

II'I'I'!'I~'

11.!J.I~. 11':lllii

I

°l"· -,'t ' 3.' -1'[' !, 'i i~!i~ ~~'"!-[ i a I.::'~ ' Z" ' -& ~-~i~ ,.01, gg:r;a

•. .U...

"";"1"

~-51 §.• l~ ~

~'§

" , '" ... ~

h hi: ••• ~.H.~; • i i .. I! ==-, ~6 iig6 ~ "i ~; ~ ~ ~ :.;s"¥" _.l . , . [ .. :;:i~.. ~~~: ~ .. a !is. l!a::;'~

"

lel.

~~,J~ :.i~~o;() . ~! .. ~!~~~ :7il -& ~

ij' ;5 I~!i!. ~[ ;'; ~. "~' g iO i~ t1 .3~;:1

'[ 5\t- "'!

,. .," i; i~~J

~s:;~

.. II

g !l.ci!

..

pH

",

.. ,6

.ll " g. H ti.s

ili~

'l'

,

'0. ~

"-

~ ~ ~

3

i: N

.l,

2-10 Engine, clutch and transmission

nul on t~. mount ing boll but do not y.1 withdraw the bo~. SIacl<en the pinchboHs on the mounting lugs lor the upper rear mounting boH, I~"" unscraw 11>11 nut on Iha moonling boll. but do nOI yet withdraw Ihe bc>1 IH. i llustration) . Make surfI the engine is property supported on the jack. arll upper and low&!" rear moonllng boilS. rIOllng tha WasMr with tha lower bolt on t993 YZF75Of1 and SP modals ISH illustration). Careful ly lower lhe engine /I IInie. lhen bring H lorwatd sugntly so mal 11>11 gearcl"\aogll $I11tft Is cNia, ol lha sidesland swilch, Ih"" low&!" il more and manoeuvre ~ 001 Irom the rlghl·hand _ . Elltw rerTIO'VII <:oil"", from lhe righl hand Iront moonting bolt lugs and the upper rear mounting boll left-hand lug lor salakeeping, noting wt>ich way round they or lightlll1 \he pir.chbolts so mat they ara held securely and camot faJl out.

assi.t",,1 place !he ""11'''' unit on top of tile jacII. and bk;K;k of wood and r;IIf9ftJIfy raise the engine iflto posJIion in tile hme, "",king SUI"II the mooming boll IloIfi aIiQn. Also IfIIIIboIts. t/wl the frool mounbng bolts, w>d ~'naIIy the /ttfr-lland front moonting bolt lug pir>chboIts., lightening mem all to IIIIJ;, spacI/itKi tod ~t 3)'S'1$m rl"lO
Installation

/ower fB8I' ""11'''' mounting bolt. Ixst leave !he rol/oosa 30 rtrel the bracirlJt can be aligned with rtre 8Jd men \>ghIM tile rot to tile specified torque.

m.

20 In$laliation Is the reverse 01 removal.

noting the following poOnt:s;

-J

MeCOm8 Ifapp(td ~ !he engine and

tile I'rlim8 W/IetI installingille engine b} Many of tile Mgine rl"lOCl boil minstllllrJd in ils com>Cl location. w1rtr lis washer If filled. !mtall aD of tile bolls and ""Is /Ingtff-lighr 0
oro.

c) Befora rile ar>g/twf m moonred, _ Install the eolian. fix tile rigrrt·hand froot moonling boIIlvgs end !he upper ffJIJ/' """"'ling boll /ttfr-1wJnd lug, making sure tile sfIOuIcJMKI ends face tile mide. or sJac}(err tile p/IIcIlboIts to ~ them If they W8tW nor remoWKI. Wirtr tile IIid of an

6 Engine disassembly and

~- -

general information Disassembly 1 Befor. di.... ssembHng Ihe 'trlglne. Ille exUtrnal surfac"" of th" unll shook! be thoroughly cleaned and c!agraased. This wlll prevent contamination 01 the engine internals. and wHi also make working a lot easier and ciNn,.,. A high fiaon-polnt ~~ent. such ao paraffln (kerosene) can be lJSIId, or belt... sllll. a proprietary engine Oegraaset such as Gunk. Use o ld palntbru~s and loolhbrush"" to WOfI\ the solvent into the various recesses of the ""glne casings. Take care to exclude solvenl or ... at&!" lrom Ihe electrical components and Intaka and a.haust ports. Warning: The use of petrol (gaso/lne) as a c/ean/ng agenl should be alIOIded because of tI>tI

*-

Ll.l.

riP

0' '"-.

Il) Adjust the drive chain slack (_ Chapt,., ,~

2 When claan and dty. BmlIIO" U",!nII on the Workbench, leaving sullable clNr a ....a lor working. Galher a selecUon 01 smalt contai""", and plastic bags 50 that pArts can be grouped together In an easily ldent if>able mar>II&r. Some paper and a P6" should be 00 hand so lIlat notes can be miKUI and labels attached where necessary. A supply of clean rag is aJso req"'red. 3 Before commencing wOO<. read through the appropriate section 50 Ihal SOITWI kl .... 01 the neces","ry procedure can bfI gained. When removing components ~ should be rroted thaI great Ioree III seldom required. unless specilied. In many caoe •• a componeni"s ,,",,,,11lI>0II to bfI removed is Indlcal"'" 01 an IrI<:otMcI approach or removal method - H In

Q Sflllf the engine end check fix lilly oil or cooI8rIf!ea/<$ befom irnt..nlng the />od)' ".,.,.

together Into. rectangle to help support tile

d) t/$e new gasklJls COMaCliotls.

on thlt exhaust pipe

e} Mal<e sure all ~. cab/e$ and hoses "'" correctly routed w>d corv>ectad. and StICIJred by ItrI)' dips 0(" ties.

f) Refill the engine wirtr oil and cooIIInt (sae Chapter I~ g) Adjust the t/Yonie and cJutch cable freap/ay and engine Idle speed (sae

Chapter !).

any doubl, r..check with \!WI \e>l;1. • An errgine support . tand can be made from shon lengths of 2 x 4 Inch wood bolted

Engine, c lutc h and transmission 2-11

...............

--.-

AImow IN IIW>amtission Rwnaw _ _sMfb .ndkris ~""sIoIl1IIrwtdl.nd

R _ _ mbl}l

7 ~ • Ic:c:omplisMcl by ..-.ing the ~ diNMImbIy~.

01_removal and Installation IA An .nol... ""ppo"l m ~ from '" h 4 Inch wood

.ngIne It ~ 1_ IlIu.trltlonl, IhouOh !he ~ ... till rWoIIy on Ihe IIat bOt:Iom of !he unp, rod !hire . . t.w PI9S al Ihe Iron! 10 IoMp M 1IabII, n. poI'IlTIIII. of IhII mcunI -'>OI.IId be jual big -.g1'l1O .ccommoda~ !he unp within M100 thallhe ~ . - on

..

-

5 WIlen diluHmbling Ihe .ngine, keep 'mal..:!' !W'la tog.t"- Qnclucllng gaars, cylinders, ""lonI, o;:onnec1lng rods, valves, elc, _ t..v. bMn In contact with ..:II _

-n-

during ~ 0I*all0nl. 'met«!' ~ "",,\ be........:l Of _ . c I as an IISsembly,

a A complela ..-g lnaft"n,mlnlon dl,· as....,bly thoolcl be do ... III tha following ~ .. aI ord.. wltll "I_ca to In. Rwnawrn. __ "WOP'11~ s.ctionl.

--

........ ........

otcoollnl. 2 ThI cooler " I0<:0I1111 on !hi front 01 th
ytu.tratIonl. 0IIcaf1j Ihe O-ring as I

"""""oI.M-. ..... it_inJr.~ (Na .... lTat/On). Locate tha lib on the ccoIat ~ !I'll on Il'Ie aaoW:ase (Na llus:lTarkltlj, CO 7Jgo'JWI the oooIar bolt 10 Il'Ie ~ Nlfll'lQspecIIt/Id II Il'Ie ~ 01 !I'll

cJ

*""

-

" , -. -' MIII:e ...... the coo/IrII " " - _

..

ptfmIIId

1ully00000thaIr......",IItId . . ~by

f) FIIa.-oIIl'J11w_fiIItha~wtth oIJ","~I).

III FWiIIIl'Ie oooIing S)'lItem If It was cftItIad,

!I'll _ in both Ih8 racfiator_ the _tvOfr IItId top lIP if necesswy (_

Of cI-'<

~IJ.

new_

~

II wtth I

n_

onalf - . . . y . Also cnd<s. '*'**'lI

___ _......

chIcIo; Ihe ' - lot spits.

"""~.1l'Ie1l 1l'Ie~_Chor¢a"9J AImow ___

~9)

AImow Il'Ie ~"*"'->ism

rn. Ct'8tIItt:aN ~

t DnIIn Ihe .-.ginI 01 and .....-.eve Ihe 01 M. _ CI\IpW 1). ~ Ihe cooing I)'Item ( . CIwpI. t~ Of tw... __ ....-. of bIocIdflg Of c:Iwn!*Ig Ihe " - to - * I ~ 10M

011 cooler bolt larrow..:l)

4 Chedo. Ihe cooIIr D
~ll'Iepkk~coI~_

S!tpMola

Removel

7.3 Un ..... w _

and 811'1 evIdtneo of coolant leakage and

Rwnaw IN C)ti'IdIr bkd;

""""-'ll'IeolJ""""

Noll: The 011 cooItK eM! t. rwrIOWId with Il'Ie ~ In 1M trlma. ' I tt.. engI... ,.,.. bMn -.Ipnc:ft Il'Ies,-1'I1Iich donot~.

n'IUIt be UNCI,

RerrIovo 0'It CJI"lOer fI«R

~ll'IeolJpump

~ ~

~

rod~_IIt.-onMW~.

Nota: The ........ COYW eM! t.. ...........:I witt!

1".",II.tlo"

- . 9'IOI'I1ha"..,. which do "",.",.,.

5

~.It-.

",.~..,the_If""""''-_

of _ _ noting

Ihe blowing: -' CIIItIIha _~......,. . 01 /fie ~_rhaeoolw...;tha,..golltld

D) UN a _

O-ring and _ I t with c/NtI

Remo"el 1

~

=:

tha _ _ tt. loWing AM

'*'*'

1_ CI>apt..- 8), tha tuellank and tt. ... fi~

~-:e ChIpter 4). -

tha rwIIItor ~

2

2-1 2 Engine, clutch and transmission

8.3b Remo ... thto lrim clips (a!TOwed) on NCh_.

:2 On VlF750R and SP models.

9>IIIDn

remov8

1M

ooIIe _ Chapter 5). DIsc:onnecI the right· M od handleber switch a od throttle positIOn sensor wHIg GOI\fItICIora 1_ -.-.atIonI. Det8Ch the Ito'otIIe ~ from the Unecrew the ~

_c;r.pw .).

four bolt8 MCUI1ng 1M coil mounting plsl. ..-.d It noting how It l'1li 1 _ lluetmlon). lift the rut.t. r.tne oil the ...... ~_. noting how It fits I_ llustration Ud). 3 On 'fV'1000R ~ I'fIIOOVOI Ihe 9>IIIDn coli. 111M Chapter 5). Release the c able ties 8nd IrM the wiring loom. then d isconntK:t lIMo

'.rn
8.3d U1t ttla ru~

8.k ..• and ,emo'" thto pial.

bam. off thto v. . .

~.-

, Ight·hand handleblor .wit~h aod th,OIlI. poaIIlon HnSOr wiring conr>eCIDrS C_ mu"..lion) R.-.se ttle four Irlm dlpa &eCUI!ng Ihe coil mountinv platt! to Ihe undeQkIe 01 thto t-.-. _ ......... " . ~

plaia. noIing h<>w It ftts (_~ . lift " , . . . - bilffIe 011 the vaIv _ _ • notil'lg _MMs I_~

.. IJrea'ew the bolls MCO.ri"Ig thto ........ _

In.raflar/on 5

e........ the ........ _

gasI<M: lor IiQI-. 01

~ordMlIIIoration_fil.

_ry

__ K

Simolarly cheek IN

rubb« (lf0lTlllMl1 on ",. COVW bOIls for cr.a... h8rOeMIg InC! deteriormion I - i. .IratIon). 8 CIewI ",. .... ....-I..,.. olIN cylinder r - l InC! the .,..,. _ wilt! IIcQl.- 1hInnIr, _ _ Dr system cIeerIer

,,"11

~

InC!_M I_~ .KIIMo_

II . tuck. dO not try 10 Ievw II otI with a l5(:,ewd,;ver. Tap ~ !J"I't/y IlJ'OUnd the IIdM wllh a rubber hamme' or block 01 WDOd to dillodQe ~.

7 FIt the guI<et itrto \he ...... cov.r. mIklng ...... It 1ocII,.. oorrectly IntO lhe ~ and the amaII tab In 1M middle section lac" the

Iront II "

ltiultr8tlon). Use I f.... diM 01

Engine, clutch and transmission 2-13

8.6 Chotck u.. .... bIMr gorornm.u. (arrowed) and .... new " " " 11 nece.-y

8.7 lhII t.b on thegnkM mUM bot at the front of til_ cove<

8.8 Apply the _1..,110 the cutout. In the heed

grea$8 to keItp the gaskflt ~ place while the .,.,...... .. liIted. B Apply a kJilabie Malant to the cut-ovt$ III Ihe cylind8f head wh8fe the gaskat halt· con:iea 1ft (see lIIushtloo). Po.Uion the ~ COY« on the cylinder 1leItd. making au", lhe ;ask&! stB)'!! ~ ~ I"" Hluslratlon 8.4b) . Install the cover boilS and lighten !hem to the torqu-e settlog speeilled at the beginning 01 the COOpt..... 9 Install the remaining compon
Cam chain tensiooer and

guides - removal, Inspection and installation

~ ~

~

Nol_: 11>8 cam chllin l"""iornIr and (1lJidfls c,""

boo ren>c>Wd wi!h It.. .ngI.... 1n rIw frame.

Caut/on: Olle_ )'OU start to ,..mo~_ th_ t""slone' bolls, )'Ou mu" ... mo~e the tension.,. all tile we, IlIId .... e' /I before lightening the bolts. The tensloner extends

811d_

tts.If In pJace, so if you loosen the boIrs Pl>'fWa,_!hen ...tlghten them, tile tenslone<" or cam chllin will be damaged.

Cam chain tensioner Remo~al

2

1 On VZF1000R models. puH the c;orburenor heater I)'IItem hoM holder 011 the 1""$Ion.... body (IH illustnltlon). 2 Unse,ew the t"".lone, cap boll and withdmw !he oprfngs lrom the tonsioner body

(see I1luslnllions).

9.23 Cemshafts, cam chain and t«lSk>ner compo<MHlts 9.1 Pull the holM I"IoIder off the 1...... &10,.,...

"'"

Infllkecam&'laft Sproc/<et &/".aus/ camshaft

"

TopcamchllinflJk1e

5 cam chain temioI>fN 6 Gs5kf!t

7 TlWISionarblede B FrrJllt cam Chain guid8 9 cam chain

2-14 Engine, clutch and transmission

3 l.InIcrM the two ,........ mc:uIIt1g bolts ..., wIIhcnw ",. ,...,... /rom ",. r.:i< of ",. ~ bkM;I<, notng which WWf up it fttI

1_ ....InrIIor\I.

I"""'"

_ 1»..-:1. •_ 0iIc8rd",.

body ~ •

a '-

11.---,..""

,"-

S Euml... 11M , - " " - comP
e ReI .... 'he .'tchel mac"-nism lrom !h, llIOuar..- pIung4r aod ch4ck !hal !he pU>ger It1 aod 01 , .... teosior1er body

mov.I IrMIy

1_ IRuetr.IIon).

ou,

7 II I .... ,_Ion.. or any 011,. " " " , _ " .., worn or 6amagad, or il , .... plOOQe' III Mlztod If! lila body, , .... mUI' ba . - . d . 1ndMdI.oaI1nt..... COfI'IPO'*''' ...

'..,sio<Mr

""-

Ilghtlfl tIM KnlWI to tIM IPICIfild torque

-;ng. 12

n"Sect"",

~ 8) IIOd _ IhIII """ C8fTI chain I, IIn.lontod and III !he timing mark, In . ,Ignment (_ Sletlan 10). If thl chain I.

ar.

"K~, tIM t_1onIr plungei' dkl not ~ wr..., tht aprIng and cap bolt W8I'II instilled. Remove the ~ again and ...a-~ M.

AgaIn

Installation

lila l-'Ontr plungtl' '" II'MI way Into tha body ~ .... trrion 1.81. I F~. ,-.1It onto thI llO'ISiorw body, ~ M "'" I........ Into the . . . .' ITIIII
t"""'"

"""*'"

chKk

tIM

timIng

markJ.

(_

Saction 10), """ IMIaII the _ _ ( _

lorque

....~IUbI,

_ " ng

I'"

13 On VZFIOOOR rnodIIa. lit t h t _ o r _ .. .,..1Im "- hoIdw _the I........

body~_8. 11 ·

Cam chain Quides Removal

thtc:am chain front guidI. 11ft n !lrnII. no\lrIg

OIJI of the Ironl 01 the c:am chIin

which

In.taUI'tlon ,. inIUIItheironl guiOe blade inlo the front tIM <:JIm ctl.ln IU...... (_ lIIu"flUon 1.111). m,klng ...... It IocIt..

loci"

corrKtly O<1to ~. . . .t and Ito ~ In tlMlrCUl-oula. II In".11 Ih' top guide 0010 th_ cylindlr ~ . .d .nd tlgh'.., the mounting 001" 10 ,,,.

torque _ling ,pecilled at tha beginning 01 tht Chept.. ~ H....'"'1Ion 1,151. Ins,.. the ...t- Sec:toon \I).

COYII'

20

10 c:.m.hafb .,.;IloIowen;removal, inspection and

"",...""

~

cao IN

w-v f'CU'Id n'"' _

how Mlocal. 1_

"*"

~

~

~ wfth

thfIlrIgI/nI /rt the fI'IImI. Place I'IIg'I

-. lIIu_Ion),

-.

Chlc:k the 8IidIog Mao. 01 tha gouIcI-. for I~_, dIIp ~ cracking eod 0Cha' oboIIcoA danIQt, IrId . - ttwn ~

NoI, I, 1111

,. Removethe_ 00.... (Me SectIon 8), 15 To ~ the cam c"-'" lop guld" unKflW lhe lou. bot" MCuring n 10 lhe cyllndl< "..d, """'ng ,''-, these 00111 "SO pMly ..,.,... !he ....... camshalt hoIda'I (_

,. To _

'n"01

~ \0 .«TIOYe YI"'. COY ..

-0.

• RaIMM ",. ratdIat moct\anIsm ..., _

apeclllld

11 Rer. 10 Section 10, Slep 2 and _ theleft-hlnd 0'IIlkIhaft~. thin tum the cranI
_

thfI

"'"*

plug ,.... Irtd thfI <:am c:t-. 10 pre ..... , ..,y ~t from dropping In/o

thell'lginl""......,.,..,..

Hot. 2: 00 not separate the c.m'llaf! caM from the cylinder head unJeu I I>IIW CUI ,. I>oI/ng Imr.ad. Retrro Slip 10 lot details oro

--

Removal 1~

""'_COYII' 1_ SectIon II)

Engine, clutch and transmission 2- 15

,-

10.2b ObtaIn _ 10.2a " - _ . . . - _ ............... W_1IM1IrnIng inspection plug (8)

, "'"

p.aJU _

a 15""" .,,~

IMtlllllIMm aa shown to !Urn !he

........,

.~

d 12mm

2 Rerr-. \he 1etI·1\and cl'Wlkshatt end· CO_. ~ by 1M" SCteWS. and ''''

tiINng ~ pIug !_ ....tralion). The ()"rI~ can be reused 11 lhey _ if! good cordllon. ~ ~ them. In oro. 10 lum !he eoginto a auilabllt bolt and colIN must btl Ihr. ."'-<.I InlO Ihe end ollhe cra nkshaft Oblaln Iha required pa.rtt as aIIown In Ihe dlegram. tt.. ~1 !he collar ooto lhe boll and II..-.edme_lI'Itome~ttandtigf1len ~

- _

a

gMI' _1Iq>Iy the ..... _ 1 0

'"""'" 11M engN lurning 1_ illustration).

A " , """ witt. h

_ttn.datn. boll

'*' be UHd lnIlMod 01 • cobr - tighlen ",. nu1egMW1""_ofthe~101oc;:k

!he boll !_ lOuelrallon). n.. ..-.gina CIIn _ be 1...-.:1 """II !he boll hu.. wming ~ In en IOII·clockwise dlrecllOl'l only I _ lIIuI I • • Uon) AII...... ,ively. pi""" ' ''' n>OI0u:yd. on en .uxlI!ary stand !IO IMt \he ... whHI is o!I \he ground. seIecI a high gear and roll" I". . . . wheel by tI8iId In its oormaI dlrecllon 01 rola llon. II .vallabl •• Yamlh,,'1

10.2c ThrHd It. boll In It-. tight... It. nul ......1 It. crankaMft ~

tooI.......tIIy. con.Istlng of • tmIng rotor. "boll end • dowel pin (PI. Not..• U8· 81873·10 or 33101·81873·10. 91317-08030 ItId 936OoI·08I(71) can also be UHd - ftI \he pin Into me ~ In ilia end of !he cranbhatI. 1herI1oca1. me rotor <MIl' \he pin ItId t'llh*! me bolt !_ MI...I..,Ion). Use \he nal' on II'1II roIor. not the boll. 10 lum II'1II engine.

10.2a yemet\e ., 8PIda1 tool CIIn"lO be used I 7nWIg I'QII;W'

2 DcweI pill

a. Mown 3 8011

.....,

10.2d T...... It. boII..-nI-cIockwIH . .

3 T""" \he Mgine unlil !he or

marl< allg ... In !he npec1Ion -.....sow !see g"" trrion). ItId !he camshlft Iobw lor II'1II No.1 (Ieft·'*'d)C'fh*'-~Irom"",*, 0111 •• end the dol on each CIImslllllI lligna wllh In. dot 0<1 lhe CIImsh,,11 hold", 1_ Inult.atlonl ). II Ih. cam lobe1I .re faCIng towards each other and \he 001& do nol allgr1.

_ me poInl.

2

2e16 Engine, clutch and transmission

lo..3b_ n...,...,shaft ~lorl'lO,' H t.cin; In>m...,.,

~

_~

olh« . . _

Ira ,,'umld '0 their orlglnal loelllon, on Installation 1_lIIultritlon). 8 Uote.- IhI CIII'OIIwIfI holder boll, for IIIe camshaft ~ wc:.-1<MI on . .a.ckentng 1hem _ t y and • lInIrcm .. at _I lime In I _crIu-crou pettem. outsidt WDI1dng

dIed~on1hlo~.ttob

towan;IIlhI """t... SIKl
• BeIorI dl.-urblng lhe

~fIs,

IT\IIII I

noll DlItMt ""*'II rnar!mgI cIMcrIb«t tIboYe ItId hOw ~ aIi\Jn, Wyou ... In If!)' doutlC .. tothe~t"'the~,orW~

.... not vltJlbIoI, makl you, own alignment marlIIt

beI_ .. oomponents, and 1110 belWMtI I looth on MCh IP'OCI
--

'""aIon..

5 Remo.... Itle elm chain 1_ 5ect1Dn 9). e Removtt the cam cIwIIn top II'Id Iront g ...... (_Seclion~

7 Bllore ",""vlng Itle clmlNlII holders, ITIIQ I notl 01 which lItl Wherl. All thl 1toIdtts ... willi ...... _ . nurnt.f to _ _ !NIt IocIIIIon - 'IN' dIf'toIe. tIIIl ~ ~

~ II lor thIlr'ttake can'lIh8ft II the beck, 'EX' dIf'toIe. It II lor the exhIuII C8mII'MIft II

"'1 tronl. The number denat. . the cylinOef

~wtkhltlitl,ie 1 to41rcmllfltoright.1f lilt .....'" I,. not visibll. make your OWn betore disturbing them - It I, """,1" they

cIIain to another companent or HCId ~ IISIng I rod 01 some sort to prI\I«lI k tram dropping. t Hthe IoIowenIIrId ..,. . . bWo
Ircm the camIhatI

CIM. _

•

con_

,",,*,,1I_1nto-.ty~_

~

roIltl tilt ..,gina antl-docl<wiH 360' (DOe lui t\6Tl) 10 u..t ~ 'T' marl< . . . , allgnI wIIh the polnt.. In tn. inspection window The ~ ~ wi! now to. taclng -.y Ircm Heh 01'* and the dolJl win to. 8Hgned , _ n g tilt No, 1 cyWndtlr " II TOC (lop

If!)'~

the seq_ 10 IIItI \hi pressuN lrom the open v."',, c.nnot coo .... thl camthln to bend 1_ lII....tretlon). Nofl ItIaI DOe boll on each .......... holder secures ,lit cam chaln lop guide and lies aIreedy been r«OOved. Clulloll: At clm.III" could brNk If 1111 hoJder bolli'" not ./..:lelned . . u..,ri_ ,lid pressu"" 1 from 0 _, ~11"

Also" _~

I". ___

ItoIdIr doH 1'101_ hom 1M held, Ute hoIdw is a..y 10

/I _

~

brNle, tf '''II~' 1M ...... _ " ca.. mil" be ..11 • .....:1 ; tM "oIdIt'I , ..

m,tchld 10 ,,,. ca •• and .,.111101 be rep/IcW HJHOI'lIttly, R.move tl'le bOjll, til.., lift off the <::amah.1I holders, noting how tlley fit. R.trl ..... th. doweIIlrcm IIitI'MIr the holder or the cemll\ett

CIIH

If

they

_

100..

1_

1Iu.v.tion 10.a.). R.rnov.!he ctmII'IeItI, rotating 1hem - . - tht _ at IhI angn.

.. yoo do 10. Kttp .. meted pMS

~

WhIle the C8fI'ISNIIlI •• 001, don·I.-ow the go aleck ItId do not rotat. the crank."./! - IhI ch.ln mIIy drop down aod bind between CfWIIWIa/! ItId case. wNcI1 co~ld damage th". compon.nl •. WI" tl>t cam chetn 10

,tie

_"""~withlhl~otQ ~..-

iI'IlhI C)'IIntW

~

ItId

'"'*'* • with ....... .......... COI"IIai"oIr II not ....... ..-w.Iod beIongI.

Of . . ~

pIIIStic blige (egg ca10nI . . , _ ~ """"'l. Remove the cam 10li0_ 01 !he ........ In ~.!hen I'1II7iew 1hI .... """' IhIIn!!ide 01 the /oIIOWf!I' 1_IIIuIt!rttlona), H ~ II not In 1hI~. pick k 001 of IhI top at tilt \IIIve UIIng . . . ..-gnet. , InWIIIICI'1IWdriYtr with to Ihe • d.t> of w- on Mttt- 111m wII _ grMM), or. ~ 1nC!. ptiI' 01 ~

, _ _ 'Cl.21I11. Do not tIowthettwn k> /ai_the angina.

In."ection 10 Inspect the ~ng aurfacn 01 the camSl'llll case and 1IOId.. Ir'ld IhI COII'1IIJ'O"dlng """"'" on IhI cemshAft lsee lIIu''',UDn!l). look tor tcorl marka, dflep _.tc .... and evidenct ot apaIllng I' pitIed 1P9N/ar>ce). II cIemege II noted or wear is ---.... IhI ~ mutt bI repItced with.- ..... To~ItMtClll'lllwftc.. lfom thl cylinder _ . _ t h e ......... bohI holding 1hem IDgIIhtr and lin on the CIM ~ iIustr'riDnI. "ft 1I.n.ck. lap"""" tilt ,,*,1 races 01 the CIMI with. lOft-tlCed mallet, Do not allerrtpl to IrII ~ by irw«I!ng • ..::rewdriver ~ IhI caN WId the " - l -

Engine, clutch and transmission 2-17 you'l damage the ~ 1U1..-. RImowt the old gIIske1 end discard It .. a ..- on. "",II be used. Not. tIM two dowels and 'ItII"IOVfI tllem lrom 11M CIM ~1 they a'e not 1I>tre, lhey will be In the heed). R""""", 11>11 011 ~pe11 from tIM underside 01 the caM end d*-d the 0-tIr0ga. tt.. lit the pipes onlO the new _ I,I&ing new O-rings.,.., tighten the boIte to the 10rqlHl ..n.ng SjHCIfied at the begRwIg oIlh11 a..pt •. FII the dowell. i'I1o the '"-' H raTIOYIId. then I8y the new I)8IIkeI over tIM dow'*-'. making lUre tIM 'UP' mark facH up. Fit the caM onto til. Ilaad. tlleo apply moIytldenum dl&ulpIllda 011 (I 50150 rnbIl1.n 01 rnoIyt;idero.I" ~or- MId engine 01) to the bc* tIY.:II end 1J!Il1en them .....-IIy .,.., a IinII II a time In a crIss-aou ~ awtng !rom the 0Intre MId worIdng ~ tolhll ~ torque s«tIng. II CtIe<::k the camahalt Iobw for r-t d~iOn (blue appeerance). IICOfI marIIa. chipped IIHS. II" '"POll and spaliing {... llluatratlon). M - . . the height 01 eKh lobe with I mi<:romel. {... mUltTation) end compare the reautt. to tIM minimum lobe ~ Iiated In !IllS

-

CIwpI".

Spacit\ca1lona. "

dameQe ;. notlld or WH, ~ eKceaaive. tIM c_11 mU!lt be replaced with a new one. AIIIoO. be aur.. to ctle<::k the condition 01 tile

12 Clleck tIM amount of camshlM runcul by &Upporllng MCI"I ...,., 01 tIM cama/l:lft on V·bIocks. MId..-....rlng any runout ueIng • dill gauge. " the runout Il
-~.

13 NI~I. che<:k Ihe camshaft journal 011 c ...,anc.... Check ONeil camshaft In tum rather than It tIM ume t'llMI - the exhaust camaI\ooft Is 1dent,IIIIbIe by Its two IcbM 1* C)iInder. end the InCake c.nshaft by "-line IcbM per cylinde< {HI Inu,tration 10.:24.). Clean the camshlft. the bRrIng aurllCM In tIM cyIindtIr heIId and camlhaft hokIers with a cl6an Ilnt-"" cloth. thin lay the camshaft In pIaca In the casa. 14 Cut some ,trips 01 Plastlgauge end lay one poICI on MCI"I )oumel, parallel with 11M t;amshaft cantrllline I'" illustration) MIke .... the camahafI "'*'- __ .. lnIteIId (HI Mlustratlon 10.2eaj Lay the I>OIdIrI In tlla;, correct place In the case (Me Slep 7). Lu1>rlc.t1 the tIY.:II 01 the holder t>ob with

lO.Ioa Inll*)t tIM bearing ""riaca. In tile camalulft ca.. and hoIdar • engine 011 thin lnItailthem end tigMen them ItYanIy and I Ii1u. at I bme In a criu-croM paftern. ....orI<Jng !rom the c.ntra of the c.....n.tt 0UIwMII. {lot startong with the bolls 1hal ..... aboVfl valves tllat will be opened wher1 the camshaft Is lightMld down). to the

torque ..tUng specllied at 11M beginning 01 Chapt .... l... Illustration 10.2Gb) Not.

IIMt

IIlat on YZF7SOF! and SP rnorHb. the ..... out. bolt on - . exhausI hoIdow Is tighI.-.ed 10 a low.... torque 1Iwm the ... t Who~t

lighl..,lno the boItl. make ..." the hoII;Ierl are being pulled ~ .....eIy down and ... not binding on the dowels. While doing this. don'l let the catn$htl1t rotate.

2

Io.IOb ... and IN joumeI

_lOll

of IN camMatt lor ecn.tctoee

~-

10.11b ....... lNheIgh1ofthe cermhaft IoOee with a " * ' - 1 .

2.18 Engine, clutch and transmission 10 ma.nlaln PfOr* l....-:.n. or II It .. .,,11 or till - . ... bindong or klrWng, tepIaoIlt w,th • ....... 001. ReI« 10 Sec1>on 25 lor ~ 18 CIIIck tIIIlj)I"OCIofIU lor _ . _ ~

_ cam ct... • . , - . _eo._..,.-ocI<eI

"."..I1""~"wom.""

-

on the a-anksheII. 1 1 - . _ .

IOola.

_-

the.", ... *'9Il'I1II'Io..*! be _

lor

I_' bIIdI_camSec:b::n' _

chI
Inspect _

20 Inspect till oul..

~to _~prlnlMI

...n..... 01

_

cam

foDoweq for ~ 0/ KOIing 01" Otlllr .,.",.. II • 1oIow« .. In poor QDnditIon. ~ • problble !he bote In whoch " won.. • IIiIo damaged. Chec. for c:IeerIIIc» ~ till 10000w... and _ . WhoIat no spec:dIc;atJoM . . gMt\. II __ • ....-.... _ _ _ 1oIowan. .".. borw . .

_t

~ _wldlh ol' _cn.hed

....

~

.... _

~_

~

out-ol-rwncl or Iaper«!. 1111 camstIIIlt IIId the IoIowera ....... , be fIiIl/.8OIoCI.

caM

Ins tallation 21 II r"""yitd. lubrocate N<:h shtm and III w,' h moIybdenl,lm dl'l,Ilphkle o~ I. 50150 ml ..ur. of molybdenl.lm dl .... ,phkl. grNM . nd 01) e
""II''''

l1>li_

marking on .ach ahlm f. c,ng up I. .. lap o/ the ...

,v•...

15 Now umcrew!tle DOli. evenly and. lIMe II a bmoIln I cnu-cro. pall...,. alarlong Irom

!tie

oulSlde ...., wor1<"'Ij towards 1111 cam...

and~lIfIotI!tIeC8rl'llllllflIloldolfa.

1& To""'~_oiIeIMrarIoI.~ !tie crust>Id plQbotl>lge ~It ,I, w....t poml) on Nclljoumllto till ec..1. prinled on the Plut~>Ige COOl • .".... ~_ Iliull ... llon) Corn"",. !tie _ to 1l'I" Clllpt..·• Sp.crfocationl;. II !tit 011 dMranca iI gr..ter th .... ~ ........... !tIe_,... of!tle cams/>lrt IOUrnaI ""til a rnocromIt.. 1_ IIklatr. II !tie1moI. JOI.'fT'II diamlt thin _ tlon). spac:IIIed _ .. II , . . ~

~

with I ' - _and I'"IChecII. 1Ila~. " till cte.ranc. . . II,. 100 \I'M\. 01" ~ Ih.

~ • I

a.fO,.

,.n....in"

th.

eamwffs, UtrI$h,,1I caM Of" /ooIdets beca ..... 01 d"",.goe, check ... Ith local mllchin.

$lIop$~ ....... rOtCyCM ~

worlt. /" III. ca_ of the cam.hall., It trYY be pouibJe 101" cam lobes to be _<»d, regt'DUnd and harden-.l, at a

cost fll" Iow.r ilia" 'h'" 01 a " .... c:I/mSh.o/f. " the bNri>g .....,._ .. Ihe _ orholdws_ If....,.be ~

'II.... '0

ou'

pe.. /tHe 'Of" be bored to ICAPI beIrlng .hHrts. DIHt to Ihe co.t oItMW.,."..,."...,tslfls • ..,...... _ 111M . . opUom be expIo.-.d!

~)cuNI"_Ib_.~1Ila

carnahert ca.. and N __ (.Step 10 for

~

witll

MW _

""*_ 01_ c.. Ir'O'!'

17 ExoepIIn c - . of oil starvatlcn. lila cam ...ry rottte. II _ chI,n lias

chI,n

w-.

.~~,_...-tt
lI11,1s t .. tlon). MaIII ...... Nell shim Is COI'fICIIy Maled In the lop 01_ ....... auembiy. ItMn Insla" N<:h 19110_. m~"9 ,~,. II fill ~u.reIy In lta 00.. t_ I" ............ ) Note: It '-mosf ~IhIIt/lleIll>lmlIlld~

... rerllfJ1el1lO Ihw rKIgitW

va/WJ;S

0I1lttrw1i11t

rr.. ~ deiItIncM ... be hllca.ltafll. 22 Mak. surl tM 1lNI1"9 au1ac.s on till e.r.I\Il'Is _ In the eyIincIe< l1l.:I ... dMn

t,*, apply molybdenum d,aulphm on la 50150 mi.t"" of molybdenum dlaulpl'uOe . . - _ ...... o-QIOMChatl"....._ eppIy~lOthe~~

23 CIIIck tn.t _ 'T' marl< on IhI rotor .hI abO'" WIIh 1111 poo'It.. !tie InlopllCtlOI"I

'n

-.dow _ SiaJl3I .... ........Iion lO.3al. 24 F~ the.>
"Iull' etlon) Fil the cam CN"n around till _tIPfOCI<et.~the_~

~et_1IId1ntc Hmade."",,*, fitt.ng po.II up on ".. IronI run 10 ....,..,... .. IIack from ~. 25 Now lit till In"", cwnshalt. klent,fi.bkI

till

cn.o-..

by ~. th... 10'- per cylindftr I'" mull"lIon 10.241) . Ihrough 1111 cam Cl\aofl _ onlO tI'III back at 1111 ca... mak"'ll ...... lhe No. I cylin
-_.

II/'OIInd tIIIlnl .... tprOCket. tllgntng 1M matIII belw .... sprock., looth Ind link II mid •.

10.241> t...y the camshaft In l1li caM with the pUI"I<;IImMI< (arrowedIlacing up

Wilen fltlln" 1111 Chllln. putllt tight to mlk. .~ .. ,,,... I, no slack bet_ 1111 IWO

Engine, clutch and transmission 2- 19

2115 "~IN camahaft holder dowools inlO the 1_ l"". lr8tlon) . Mak. __ In lIMo hoIdIfI _ cIewl. then Ipply moIybOerlum dltul5lhkM 011 II 50150 ml~'u" 01 moIybd..,,,m dl,ulJ>/lkl. g"IM .nd engin, o<~ to them. Lay the t - . in their comoct pac. in the caM 1_ s~ 7). tt.... ~ !he cam chain lop QIIide 1_ 1,,*",1Ion I .I!5J. l.ib'icIol. IN ItvMdf, of lIMo ~ boIb WIth engine 01 tt.. INtaII cy\ond« _ lIMo ~

..n.c..

lIwn.-.cltlghl"IIwn~.-.cIllllleat.

lime In I _ . _

poottem, WOfIdnIIrom lIMo

-*"* 04

lIMo '*""'>aft ~ (Ie 1'**'11 with the boIb Ihat . . abcM ........ tna1 will be 0peM(! when the carnshll1 .. tightened clown). to 11"4 lotq ..... "",~ng apeclfied . , the

csmshIfI round II rIQII"ld, !hen m the onlO the camshelt, end check 1M marks again. With Iverything corrt(;lly Iligned, tight.., the sprodte4 boll, 10 ItII torque oe!ItIg spacit'IId at It1e beginning oIlt1e Chaptflf. C.,,'ion: If Ihl m.1'II1 .ra not .llflned 1X1C11y • • dHcrlbed, Ihl ....In riming ...HI bot InccItNct _ ",. v........ mq . - . ",. pisfMl, c.ualr!g _ ...... dillNIl' 10 '''' .tp
.,>oj

-26

Install the """ cha,n Ironl 1I,,1d1

1_

Sect;oro 9).

dOwn_

21 Install !hi cam cI'IIIn tensioner ( _ Section I). Tum the angi .... sntI-clockwiM throogh two IuIIII.m8 .-.cI cheek II(I&In 1I\at all 1M liming rnar1<.t Itil 8Ugn (_ $ lopI3 and 4). 30 ChllCk Ih. v.lv, cl....II(:" alld Idjull ItIIm Wr-.IIY I_Chaillflf 1~ 31 If UMd. _ 1 t I I coIar Of ntI1l1"1d Dolt ot timing pll" IUM1bIy from \hi lett-hind _ of IhI -1IIIct. gNf _ ....

c..ttion: 17Ja.,.",."." ,. .. 0rNk If" ;. IJgItr.,...;t do ...n 0.110 'h. c/oMd before 'h. Open The holden . ra 111t.1y 10 bra.1t If IhlY .ra nol Ilghl.ned

ItII ' - brake 10 ~ I ItII engine t"'"*'ll wtiIe IIIcI
--..y-sq~.

0<MIf IC""""

27 UIIng I pIaca 01 woodin dowel, P'"" on ,"- bIcIr. of !he c.m chIin , .......... ~ . .

32 Il\$IalllhI v.1Ye CQYII 1_ Section 8),

beginning 01 the ChaPI'" I'" 11,,1I•• llon). NOli thll on YZF150R alld SP mod.I •• Ihl ,.... out.. boll on IICh " .hlUII holder It Ilghlened 10 • lower torque lhen 1"- 'MI. WhU., IIghlenlng the bolt •. make __ the _ bM>g puled IQUIrIIy _Il0l I*'Idng on !he _ _ _

~

...,..10

v.""' •.

v.,....

11"4 ' ....Ion.. 00<. In lhe cyllndet block 10 """" lhat any &lack In ,"- cam chain b I l _ the cr.nkshafl _ the inlakl -.-tI. II"Id ' * - the two QmIheItI. 15 IIkIII L>P II"Id ~ to the . - IUI'I of tIw cI>aIn fw'het. " d i a l . III ,..... \III by the 'enlloner), A' this point chef;k the, In the ',mlng mtrk ••,1 .WI In IX.ct .. Ig"..,....,t IS dHcrlbed In Steps 3 alld 4. Not. Ihlt II II IUY to be .hghlly out (onl 100lh on thl Iprock.,) ...1t1>o<J1 t he m.t1Qo IPPH'ing drlStlcllty "'" 01 1I1grman1. If !he rnar1<.t art cui, -'tv wtW;:h sproci(et 15 rnIIIIigr>Id. tt.... _ i b bob _ sIIcIa' oft !he c:.rnthIII. diMnglglo It from the chIh. Mow the

"*'

11 Cytinder '-dremoval and InstaUalion C. utlon: Th • • nflln, mu.t be compl.tlly COOl bot,.".. btfIin"lI>'g Ih/l ~ .. IN I". cy/Jrtdet' fNoId mq beoomI .....-ped. Notl I , The qI/ndfIr "-<1 CIrI be ..moved

-.

wtrh_Irl(lIOw"_~If_~hIs

o...-./grIo:Ir.ItII.,..,._don'r

Not. 2: As Ills pou/bII f(I",., I"- '*II chI01. If Is IIOf nacess&')' 10 _ .". CM71ShIIIs ",hen remo.,.;ng ,he cy/irtdflr hMd - ..fer 10 SlCIJOn 25 fat" dltr. on how ro spIII_ join I". clleJn, laking nol
dactlbed.,

~

_-cov.. II> II ..

~1i9d

1000que 1IftI\lng.

10";'1 1_ _ _ _ _ 1nsptoctIon

plug .......

new

0...--

:::.,tor~~~es::.:;::~ ICCNS !he holes. Rtttw 10 SlCliOn 10 If>d poIllion !he cam_In II desctibad in 5.,.,3_ 4 -the/lOla toOl"*, be_tty pmltlor>ad II I". 1tIQI.... "... btln COffflCIIy buill, this wiN ",rom.llcIHy poaJtion /hi splilW b e _ the Clrl'lSMft I{JIOdIItI. 110 Ihete I. 110 need 10 tum I". c.m~'" .ftar \he chM'Ils 18rI'IO>«I. _ IhouId not be doni. If the chI01/s nor pt1IIIIJonad wIm l1li $pM_ trlIIfW when !he csmUliIn _ CO11111 the _ Is visIbIa Thh will ........ the cwnshIIts .... nor cornrcrty pos.tjoned, which ..-.. IhIy wII _ 10 bot be tumad IItar !he cJ,.;n "... been removed 10 • /he holes fill. could cause. ",1Ve 10 eon/ICI • piston, e.uslng nrious lU""l1'. .nd so the camshafts should ~ bot I9JmO\IId prior 10 .......:wIng ,he eyflrtder heed (Me s.cliotr l tl}.~_~_nuts

if rtqUhd

1AIIi'lg.~_Itwy.,._UIInMn

2

2- 20 Engine. clutch and transmission

Willi the C8I!"ISIMItb tt .wu. Jt .is not pOS$lbM to IuI1y ........... the eylinder _ nuts end ~. lID g""" e-... """" t» IMen .,., ..,.""" 1101 10 eodt the wa$IIars 01 et'OS/Iflltud !he nufs. s.,.". sp/iftlflg tIN c.m 1;1IMr. ~ • . . - . . . link .,., the eII*n .,.,;J. 'oofh .,., the ~, .,., Heh lide of the split link so fIl'" It cln be InstMl.i tt ....:/1)' t1'>e u,", position. 1N/dIIg the f>'1*'fI .... 10 .., up. II the C)'Wldw '-d .is '*"fI ~ Pr>g_you ... ,..".., thel 1t>Ity ... tt good r;ond;rion .,.q c10 not fIHd eheek.mg. If I>owever the W>f1Ine I, Minll "11.",, down beCausa of gfmftrtJl wHr and~. It is ofCOlHW ~ 1 0 _ the camshafrs end 10 clMek !hem CMefYlIy MltIgwtlfl .. otI'/IIf~".,the_ 01...,.. ~ tt .-I . . . . . . /my pMlCiM 01 the o\.
"*"

,... could...,.,

be_.

the c:wrJ;S;/'I;Ilts, you thodd c10 so. Note rn. 3: Do noI _ the amshah caM from qIioIdw un/IoM " __ "

MpII""

beIng~.

for

FWar 10 SecbOtl fO_ Step fO

de_ at-""".

Removal 1 Remova

tha

uhaust

tyltMl

ll..

C/'wp'. 4). Plug the axl'oaust port. wtm d6an

",.

2 Remove the CMtluratlcn (see CMpt• •). Plug 1M intIIka mIniIoIdI with c:IMn r.g 3 ~ the \/IIIYa CO'* (Me Section 8j.oo the carnsIWt8 .,.q ~ lSM SectIon 1(l) lsee Nota 2 1IbOve) 4 On al a~cep! 1m...-.d 1994 VZF750R and all SP mo<:IoM. IIit/Iar Oetach !he..-....m " ... ot! hc:>aM from 1M ItItaka mIniIoIdI. 01' . . . . . . . lhol hoses f.om u..I. <:lips and coli them ....,.,...;j the mII'IiIoIm 10 tr>ay do not gilt In the WWf l_ iI...tratIon 5.7., 5 [)rein thol cooling IYStem <see Cllapt. 1). Remcwa

ChapI.3).

tn.

tlle<mostal

housing

lsee

t On YZF75OF1 ...-.d SP ~ ...-..orew the banjo bolts Mc:uMg !he 001 I\oMe. to tn. cyhnd. hNd and detach tlla 1\oMe.. On 'fZF1000f1 ~ UI"IICreW pips berfo bolts and bracI<et bolt and _ _ _ tlla pipe (I" mUltr_Uont). Oiacllfd In. bIonjo bolt sealing wuIMors as new oneI ...... , boI USIId. 7 SIac:ken thol plflChbo~. on lhol mounting

the"

lila r\Wtt-1\and fmnt ~ moooling tIMon ""sc"w 100 .emove tha righthand and left-hand front ~ mounbng betts. notn;J tlla whh the left-hand or. (see ~ 5. Is.,..-.d b) 8 The C)'IIndIr hied • saand ~ !waive nuts ( _ I....t .. tlonj. Slacken the nutl - * y arK! • lit!...t a In a .......... of the numeo1caI Ilght..,lng Mq.......:e e.hown until they _ all alack. lhen • .....ova the nutl and their ualng .,;u,. _ """IIfIR{. a ENW
IoJOS for

boIt._

w-.

t",,.

w-..

-I

up orr the block ( _ t!1u.tr" 'Ofl). It II I. stuck. tiP around tha

9 Pu!I the c;ytloo", _

Engine, clutch and transmission 2- 21

•.. and the ee-ntre nulS ue.ing an

.""'"

..,It·

joInl 1 - . ot lhol cy!,na. !>oad wllh • 1 _ ........ to ,... the '-d. 00 ~ .ttempt to free lhoIl>Md by lnaertlng • _ d n _ ~ !he '-d _ cyIir1<W block - you" o.rnao\lie HalIng .urlKes. R...... v. lhe old cpnoar hMd gukeI _ <*card as • ~

_ ..........t be UMd , _ MlI4rr.t1on) to wtheV . . 100M. _ t h e doweIa In>m !he C)finder bIoek 1_ IIustn!tIon 11.1 ....' . W they &ppNr to be mIeeing they .... probably ."",k Nt the ~nde<slde 01 !he cyllrtdef ~d. Remove the eolian from the rlgM·hand Iront &n{jlne mounti ng lug. for ""',","ping II rllQ~I.Itd. or tighten the plnchbollS 10 k"p them In pIeoc. 11 Check the cylinder !>oad gaskel ar.cl lhol MIIhng ..,,-I..,.. on lhe cylina. head and block lor alone 01 INkage. which could

Itlodlclte warpage.

ReI'"

III $eo;IiQl1 13 ItlId

checI< the ~ oIlh1 cylinder hMd.

Installation 12 ClMn all I•..,.. 01 Old gasI<et MIIlerial In>m!he _ _ bIod<. W. ~

~

• 1.IMd. \.like c.-. not to aaatch or fiOU08 IhI toft ............", e. ~ not '0 1M any 01 the g_.t 1 I.~ Into thol e' llIIkease. the cyIl_ borM Of the oil passages. lubricate the cylinder bor'M wi'" ..w Mgine 011.

m.'....

lUN C_fully lilt the head UfI olf lhol block ...

1I.1Ib ... then remoWl the 11"",.1

and I' Now tighten the pir>chbolts on the mc:u'IIIng IuglIor IIw WI-hInl IrnnI mounting _lOthe~

".....-.d.

13 Instal The coIar1; lot the "",. hand front mtIlJ'ltJrtg bolts. making ..... thIoIt ahouIdINd ..... bee The inIIide. 14 E~ both cylinder head IOIId block MIIt"'ll ...-I........ dMn. "tlIrI'>OYed. lit the ck>wel. Into tM cy!lnde- block. tllen lay lhe n_ head g.lkl1 In plac. QI1 1M block, mlklng lur' It locII.. COITKtJy o~... th, dOwll •• lhol 'UP' MIl'" lac ... uP. and . 11 the ho:Mof .... 00tl'IC1Iy ~ 1_ IltL>&tration.) N _ ..· ..... the oId~. 115 Caralully iii lhol eyllnde- head QI110 thol block. making ...... It locates COITactIy onlo thedowell l_1Iusvation 11.9101. 18 ~ The * - 01 the cyra._ ...... willi ....... angina oL InstltoIThe nuts """" that. WM/'4Q IltId light ... them f\ngIr-tighl. Now ttght ... the nutI Irt the correct ..........teal MQUenCe 1_ lIIu,tratlorn 11.8a, b tonapI_ 17 install the right-hand and MlII-hand ..... Iron! rnountlrtg DO/Is, not torgetIIng the _ _ _ wItIllhlllolt-r.nd on., _light"" !ham to the ~ IorquoIMIIing 1_ llluatratlonll5.1\1t1

11.1 .... Lay the new lI""'elov.The _ . t-owad)...,;! onto thehHd.

klrquL

18 On YZF150R _ sp . . - . tit the oil ' - onto the cylinder hHd. '*"II _ MI/Ing WM/'4Q on each . . . 01 The unIonI. aod logh1 ... IhIt banjo bolts to the ..->fIad 10rqua MItlng. On 'fZFl000R modaIa. o.taII the oil pipe. using new _Ing washoIn on ..", IIde 01 the ....."., _ bgItt ... IhIt t.njo bolla a"Id tile clamp DOlt 10 IhIt epaci!Iad torque HnlngII_ illuelrationa " . ton
" "tlIrI'>OYed,

instllli tt>e coolant outlM union QI110 IhIt bKk of the cyIindoIr hHd. using ' O·r\ngI . . - . d with _ . and tigh1'" the bot" to 1ho1 .pee,fled torque Moiling. Att.ch the hoM 10 the union and tighten the clamp

.-...tv. Fit tt>e ttwmostat houaIng onto 1M

\IIIIOfI { _ ChIrrpt.- 3). 20 On.n except 1993 Ind 1!M1.4 YZFT50R sP modaIa. aither .ttach the 'JICUI,O'II ,.ka-off hoMs 10 t/Ia Intake MII""oId, or HC\ft !he ' - In ~ clips.. accord"", to your ramo"'" proced.... {.... ....tratIon 5.7a). 21 lnalill 'hi rama,nlng com~" in I _ refarrlng to lhol reI",.nl Sections or Chapt... {.... Stepl I. 2 and 3). Fill !he cooling system { _ C/IjIptwlf,

...,;! ..

oIlhIir.....-.owl~.

11.141> .... maklng.no the 'UP' cutout \Im)wId)..adI!hI right way

2

2-22 Engine, clutch and transmission

'2 ValYesJvalYe seats! valve guides -

servicing 1 8_.". 01 the comple~ nalure 01 tllis job and the spacial tools and equipment required. most o ... n.", leave """icing of Ih. valves. .OiI"" _I~ "'"'" val. . gui
12.1 Check" around th40 edga 01 uch va"'a for aoIvent INkaga

"""*"

com!ct~

by pourlng a small

IIffiOIInI 01 into aach 01 tha v""'e perU. Illha sol",nl INks paSI any ... alva Inl(> lhe combustion chamber area lhe lIalv. flI not seating and sealing correctly (a •• IlIu. tration) . 2 You cao also r.mova the valves Irom ItltI cylir.der head. CINn lhe components, cllack thoom for wear to IlSM$$ ItltI extent 01 tile work needed. and . unl", a ... alva service Is requ ~ ed. grlrod 1r1lhe valves (see SactiO<113). The head

can theo

be

reassamb4ad.

3 The daaIer sarvic:e ~,"""I wiH rarTIOWI th40 varves and spOngs. """"'" ilia varv. and guides, racut tM valv....ats. chack aod r..-.- the valve spr;ogs. spring retafners and

mechanic. Th .. way no expense is irlcun'ed W the Inspection 'e"eal s Ihat overhaul Is not required at this time 2 To disassemble th .. valve components

... ithout the risk 01 damaging Iham. S valve spring compressor Is absolut.ly "sential. Make sure ~ is sultab'" lor motorcycle worl<.

Disauemb/y 3 Belo." proceeding. s"ang. 1(> I.bel and sto'. the valves aloog ... ilh Ihel' ~at&d componenlS I
collets (as roecessary). replace !lie valve seals

7

B

wilh n.... oOft and reassam~e Ihe VIIlv. components. 4 _ IhII valve oervk:e IIa!I ' - ' performed, the head will be in li ke--roew CO
, 3 Cylinder head and valves disassembly. inspection

and reassembly 13.3 Valva components V_spring

...

Spring S8IIr

, ,...

7 V&'VIIsramoil

13.S. ComprasMlg th40 va"'a springs "",ng a val .... spring comP<'*fl8O'

1 A3 mentiooed In lhe prev\oos section. valve overhaul ahouId be laft to a Yamaha deal .... Ho ... a".... disassembly. cleaning aod inspeclion 01 Ih.. valv.. s aod ,alaled components can be done ~I lhe nacestary spacial 1001,0 a,.. available) by Ih. home

13.5b Mak" ...... the compre-ssor Is a IlOOd fit both on the lop •.

6 Compress the valve spring 00 t"" first VlIIve ... ith a spring compr.. ssor. making su'" II Is 0DfT1IC1Iy IocaIeQ 0010 each e
,sa.

._-

13.5c ••• aod the bottom 01 the va"' ..

Engine, clutch and transmission 2-23

13.Sf "It-. ............. (21 won't puI through It-. QUIdII. dIIbuT the _ ........

the Colet gro<WI (1) inlo lhe head and deburr u.. .... around lhe coIIel g
lvaHable, usa PrvssIan bI\.Ia to det ........... 11'4

(_~!ulJtl'etion).

teat .... Ith the ""'lIIan blue. lhen ins'llI lhe vlllve and rot.te II ~k and forth uaIng • lapping tool. Remove IhI "a!Ye and chick wIwIhIr Ihe ITIQ 0/ blue on 1hI . . - if unitorr'n _ oonllnuoul around !hi ......... _ 01 the

I Rep6ioI Ihe proc.d ...... lor I'" remaltllng ......... RIownbIr to keep u.. ~ !or ..a. vlMiI 10QeIhef .".,. In orW SO lhey can bII ~1nu.._IOCa;\o:)I'I.

7 Onc_ the valva "".... bMn "'''IO"ed and ~. pull u.. ......... Item . . . off the top

01 11'4 vllve guide. with

~ I e ..

and discard

IhIm (the old -.~ _ _ bII reuMdl. I Next. o;:Iean !hi cyhnder I\Nd with "*"-"t and dry It thoo"oughly. Compressed .......11 epeed the drying ~ .-.d ...... thai .. .-.d ,..,..., arMS . . clean. e Clean all of !he YaMil e,pnngS. Coliall. II1d &pring teatt with soIvenl and dry lhtm tlloroughly. Do IhI part. from one al a limfI 00 Ihll no mixing 01 parts

"'*"

IlIte'" 01 varve Mat wear. Urulo.-miy COlt me

c:orr.,;t _

. . epacI!Ied.

14 Measure I'" ".Ivi l1em dllmet" t_ IIlu . tr. tlon) . C~.n Ihe val"e guld.. to "move any c.rbon bul l d-~p. then measure II'Itt inside d,amet .... 01 II'Itt gUldM (al both _ _ the"..",. 01 the gUde) """' ....... hole

IPUQe end miCfomet" t_ The guIdH ... ..-..cIlllthe

IIustno1IonsI

.m and I t lhe centre to de1amIlne "

they ... .... om In • beII·mouth pall"," (""'" ..... a'the ends). Subtrac;1 the II"," diamat" Irom tile v.... gUde cto.ma\" to obtIW11ha """'" stemlo-guKle elMrlnce " Ihe s ,em-Io-guide cIaIrInca i, than H.ted WI thIS

11'""'"

Ch.p' ..... SpecrIicItoons • . -.... wI'ooc ........ compooen1.

_

.... om

beyond

1M1r

specification limits. " the v...... gUde It wtthIn apeciflclltlOlW. but II; wom u.-.niy. ~ IhouId bar~.

1$ Caralully In.~t eaCl"l valve tac;e. lIem and colli' groove Ir" lor crack •. pits and burned spoil: II- I....motion) ~ 1hI

..- maovon

~_ ~ ~

10 the

ret""""

".1....

--~

10 Scrape off .ny dlPOflll thaI maV "".... Iorrned on the v.I ..... \'*l 11M a moIonHd ...... bn11t110 ......,.,.. ~ from the".... ' - ' - and - - . AQaIn. make ..... the ......... do not gellrixed up.

Inspection II Insp.ct thIIl\Nd v..-; CItI1uIty!or cracI<s .-.d ott. damage. II CtICI<s . . Iound •• . '-d ... bII <equired. CNoek the cam t..Ing ...-teen for .......... and .-.idence 01 seozurtl Ct>.ck the camshlfts to.- .... _ IS well ( _ Secbon to). 12 Ualng I precIsion s lrllghl-edge and • feeler gauge MI to lhe _~ I",", lisled In the specifications .t the beginning 01 Ihe Chlopter. ct>eck 11'4 head ga5l<et mallng """_ tor warpage_ ReIer to Tools aJld Workshop JTps (Section 3) In the Refer~ MetIOn!or"'" 0/ how to ..... the sl71Mght·

2 13.13

~the

_ _ _ witha

....... (or lor 1IfMI" Pfec:\lloft ..... ~

~"...,

-

1 3 ExItrTWIa the".... _ I n the COIT'II:>I..-tion chamber. If lhay ... pined , cr8Cked 0.- burned.

u.. heed will require ....00. beyond the S<X>JM 0/ the nome mect\IIIuc. Meuure the valYa - ' width and oompate It to this Cl\apl... •• Sgecd1catnw ( _ . . .Imlon) H It ~ Ihe ........ Iimot, or II It varIII around ill r;ircumler~. vaIvI _ .. It ..........,.. "

13.14b 1....t • .",.aholelJlUllOllnlOlI'I " .... ~ ...cI.apand ~ SO ......... I alight chQ wMn It's puIId DIll

13.11a Mea __ It-." .... II_~ with • rnicrome1..-

2e24 Engine, clutch and tran smission

13.1S. Check1hoo ..... __ tA), IItam 181 and coIIe1 ",oov.lc} tor ~n. of _.....:I

'"-

Speclli(:lIions 1_

1,luI ',l lionl ). II II ..

IhInrw" IhIIn ~, ,~ the valve with • new one. The mllfll,n I, I.... portion 01 the

........ '-:I whid> II below 1hI ........ seal 11 Rotate I........Iva and ~k -'Y obvious ,ndlcatlon Ihl! II i. be'n •. U.,nll V..flIoc:ksrod I dial """"If~ IhI ...... a.n f\IfICl./I rod ottmpfn !he . - - 10,IlI specIIicalions l_ Illul traUon). Illhe measurement Ixcee
'Of

...-..

~

13.15c Measure !he v"'" m..."", dIIc ........ 1hown

13.1& Check the ve"'" atem forfUl"lOUt '*"II V_block, and , dial ~

~_

~.

lhe ..... ..-.d

provided thel IhI _

be \JI1l'-O'd dc:Mn. 01 .tern above IhI

call

cdIeI~lIftef~illlIlIIIiDWIL 11 ChecI< the .nd of MCh vllYe Ijlring lor _ and pittIng. MHSUra \lie sprirtIj tree

hlnglh and

13.", M....... thetr"~hofthe va"'" lSpringa

_.

13.11b Check thto " ...... springI lor

com~ ~

10 lhal listed In \lie

specificai lOflS 1_ 1II...,raUon) ~ any aping I, "'orter than .peei/ild II h . . oagged and must ~ replaced with • ~ 0ftIt. Also pia.::. !he spmg uPflght on I nat .....,., and a.ok It bend by ~'ruIer It 1_ lliuw.otion) If !he bend in In)' spring .. ~, II ...... ~ fepIK
.,nst

'Of

18 CIW:k!he spring _ _ _ r.d coIets for otMous wear and cncks Arty CjUe5bonab1. Pin, ~Id not be , ...sed, II "'11Il,iIIl damallfl WIll occu, in 1M evenl of filllu" during engine op«lIlIon. 19 ~ thtIlnspecllOlllodlcates that no overhaul WOfk II required. 1M VII... componer"l can be fIiOstailed In 1M Moad. If any new val ..... _ being "'-"lied, lhey can ~ kMnlilled • fQllOws, on YZF150ft ,lid SP models. !he l..naual ..../Yes ' " mlrkld '.FM', the out.. Inllke marked '.FM', and \lie centre IMI'kl vllYto .. marlt.ed '.FM.' 1_ lIIust •• tion) On YZF1001)R models, \lie I~hatnl "Itvll ,re marl<ed '.SV·, 1M OUler Intak. va lvII .re ""'ked '30"'", and the centre inlai<e Vii". I. marked '3GM.' 1_ i" ...trlItlon).

v_ . .

13.1l1li Valwloc,lionI VZF150R and SP ~

OVIWi'lta/OI ...... Oan!reinlalol .....

""""'-

13.1a. V."'llocItiontVZFl000R rnodeIa OVIWkllaIoI~

OIntreinlalol .....

-~-

Reassembly 20 Unless

,

........

__

has

been

pertormad, betOfIIlnItaIIino;J the . . - .. the '-:t they IhouId ~ ground In (lipped) 10

. . . . I poIIIM .... bet-. IhI " " - r.d

';"'."':~3tg':··~~.1 "·'~':i'.-I 3,.~W··~

:i~I!.I~II!il 1!1!'='i ;<~<~'·"i~3 -,!.~¥'ll

" •••• l i l . .••.

".111

i~lmfi·~flllli:!:~[ ~

r!il[! i!ltJ!llil!i i ~:~~ia ~~~~~~_~:ii~~

1

1;'1 1• li~!!~!iJr'I'i

':11<[= lii!llli [1.11 it~.,. I w!. III_I; .,.li!1 ~.II. 'm~I~. ~io.a.~ ~a~~5

"-1

.l .0 CO·", •• , •• ii!~ r ~HH !n t ~~ "~ '" C'".i!

""/5

",3.!J"'~:

;-i6.

g

~~

~ "' <"!~ ]~!!

01

i§

.,

l~

1Q. "'iJ~

;.¥':' :"1[' nt l ,. ·!.i:i~i ~ f~~!;;, i~i 5' 31 c 5"

il

fsi~2:

,,, _ ,",'"is

g

g ..

l!lif~!!~ '-t"'''' 35' "'i g. l

• 3· !-R[: , g.3'~

<

i

l1f~l

II

II

"''3.i


::>

C

!!S"

llll-I~ ~]! ~ i l 5'!:!!C

~~~ :0. 0-, C il .. .3~~!O

• ~i,if

•• H

'"

.~ , • 3

i

~.!!.i'i

",.;:;

~(')c.

.g~

Si ..

0

~

- ...

~!'

g <. c.

0"-

,

~[

",-_!r

0

iI~

l~~' ~ liii' ~ ~~

~11~~~I~;g.g.I:~~~<>'::>~I "

~~ ~I ~_~i;!~~II~o!£i I _ " ' _ [1 ' . - !~<. I

g.:_o3- ggi ~~!lif i~;I!"2.i ~~

1•

... ~~ r'I!·· .. ·· ,n Wi ~[i~!!.~~ha~ iii~~ :~ig.~g- ~ '"'2~~i~1~1 ~~ ·'!.'i 't., ~7r i"·· ~. ... .. - i ;::~- ;~ ~~!o .. ~ [\~;~i oi.~~""iil:,..5.f~i&i~;;"· :~g

•

.

'" o

~

"1

•5.

S'~3a -~~!l~"'!~·ia-3,..~g§'g §~ "--a S'Zit.6ii[f=,.. ·"l~i"'S~ ~

-

I

. :>:>'<1 -< ~"!!.-" ,il!!. ! •••

,o·

~:::r

0

1;::>"

.6

""i"

I; .

..

i

m ~.

. . . . ,, "

-

3-!(:>

'V·"~' 3 i~:r~1~ 3- $~~l

is:

~

~.

N

~

2- 26 Engine, clutch and transmission

,~ ~

valve aprIng COITIpreSSOr lind InIolan lIMo ooI~

Remolfal

!_ Itlu,t,aUon). When COf1'lpr..,"ng U",

1 Remove ItMo cVlino.. Mad (see 5a<::1lon t 1)

apoing, do 10 only as far a. II oeces"'Y 10 IIip Itw COII8tI Into ~. Maka 08tt811l IMI lIMo COhI8 _ oooanIy Ioc:bcIIn lIMo ~

2 Unact" the bon MCUMg \I"Ia coolant PIIM from the WlIIar pun"IJI to \I"Ia Inlet union on ttw

.-. 28 Support ItMo

~ I>Md on blocks 10

lIMo vaMoI ......, contact lIMo ...orkb8nch top. then Y8f)' Q«llly tap 11>8 valv8 ,111m wtth a IOft-jacld hammer. Thla wH\ t>IIIp _ I 11>8 coleta In the groove

~

ChltCk far propar .ull", ot ",. ~M\IN by POUftr>$._1I I _ of -.n,In,oNCh ot ,he ~.w. pot1.. It ,he ...w.n, /oN,... pair a.., "a"'- In,o the comlluolliolt chambw ..... •

..

--

'h. ".1118

~ openI/on ..... Ihat,,~ IhouId

20 RaPHt the procedure 'or t1>8 remaining v........ Ramambe< 10 keep the paris for

""'*' varv. together and separate from the oth..

vato.w 10 ItIay can be ........ Ided In lIMo _ location.

14 Cytinder block removal, inspection and installation

~

~

~

Nota: 7ht C)iInder bIocII can to. removad with r1Ia en{jna In the ".,.,..

back 011I"0I0 block and remove the ~ !_ ~) o.card the Q.moI_ ,-or-. mUSI be uMd. Slacken the clamp _ sacurIng the 01 COOler hose \0 the rIgtiI"'-I end of the Inlet unIOn Ind deIach tlla '-e. If requirtod, UflIC.aw the bolt. sacu"rIg t"union to the back of ttw block lind rMnOYe lIMo union. not ing t"- ca.bu.ellor bntatl1., hole clamp wl'.e" 1I11e
"""'" or-. mtI$T be UNd. 3 Hold the cam Chain '-\? and tifl the cyIh;Iar

bkK:k UP. !hen pass _ cam cNlIl dc>wn IhrougI"I INII.R>IIf t_ a.tr8tion) 00 not 11\ IN c:t... htlinlo IN ~ - IIICI.ft II WIllI apleca ofwh or..- t:.r to ~ II 110m doing .a. If IN block it IIuck, ,.., IIrOIn;I IN jrWlt ' - of !he block with a soft-'-*:! millet to !rae ~ from IMa o;:rankc;aa. Don'1 ~ 10 tr ... Iha block by In...."ng a lC1'ewdn_ betwM't ~ lW\d IhIt CfMkcase _ you" cIa'nIga lhe ~Ing .url8C;ft. When I"" block Ia - - , WIld-.. ragalrtUld!he ~ to pt--.t anyttW>g Isling no !he o;:rankc;aa 4 fWnoye lIMo gasket and - . .. Iracw of old gukott "",'erI8IlTom the cylinder block

and CfWIkcMa milling ""' ___ If. _ _ it us.!. take car. oat 10 ICnuch or II"'Jo- \hoi .aft........". Be c.-.fuI oat 10 IM.-ry of \hoi gaal<M meterllll tal/Into I"" crankcaaa or 1"oH~.

5 Remove 11>8 dowals I.om 1"- maHng aurf_ of !he c.ankcase or \hoi ~ of the bIoc:l< II lhey .... 100M ( _ 11lustr.tion 14.1&a). Be carelul nollO drop

u.....1nIo the..-.golS.

Inspec tIon caurion: Do _, .tt....p, to

'*-" from Iha ~ block.

14.8 Mall..... the cylinder bono In the ~

~,~

--

__

wittl.taIa~

- . . . the gauge with.

_",'a ,he

8 Check lila cylinder waHl ca"'ully 10' ""'aten. and IO(q msrk1 7 Using .. pracilion stralghr--edglt and • ,.... gauge lott to Ihe warpage IImll illild In 1"~"1Ila baginnIng 01 \he ChIpter.

cI>eo::k the block IJIIkott mab~ surlaea lor warpage. RaI..- \0 Too/:r and Worbhop r(pol (SactJon 31 ~ !he AtoI-.ca sectlOn lor deIaII of how to \1M INII7II9tt--edglt. If ~ is

_.casllve the -~

block mu.1 be replaced wilt! ..

8 Using rel8lCOpjrlg gaullM and , moe""",,! ... (see Secr_ 3 01 Tool! .nd WOtbhop r(pa). <;heck 1"- d,mensions 01 -.;h cyInIoar 10 _ the amount o f _ , ~ and 0Yl0b1y. ~.- lIMo lop (but baIDw the ....... of IN top I*Ion ring at lOCI.

can,... Ind botIom (but above Iha ..... of

\he oil ring at BOC) of 1"- bore, both paratIII to

anct .ero... lila cranksheft axis t_ lIIustrIUon). Compare lhe ,Hults to lila ~ II lhe bagonrung 01 the Chapt. II If Ihe precl .. on mellu"ng lools ate nol avalleble. I8l<e me bIoo;lo; to a Yamaha ~ or apeclllilst motoreycle repaIr shop for

_lIndacMc:oe. 10 If \hoi cyIindert . . worn DayorId 1"- . . Imit, or badly Kralchad. scuffed or 1COr1d. the cylinder block mual III rebofIcI. Y..-.suppt,rone~postort(..o1jrrwTl)

11 II lhe t>k)ck and cyl,/Idats .... in good cond~ion sod 1"- pieron-lo-bore clearance is within spec,fic.Hons ( _ Sect,on 15). Ihe cylinders should be honed (d.-glaled). To perlorrn this Operat_ you will need lhe propet sIza fIaxibIe hone with flna storloIII ( _ Speciabl Tooia In T _ and Worbhop rIPS In 1"- Ratarenca a.ct>on). or a bonlol-bn.iIh type hone. planty of hghl Oil or horung 01, --'ragallndantilllc:trlcdrillmotor 12 Hold IN bIoc* IIIdewayI tao \hat !he bora. . . horIzomaI_ than v.tocaI) In II Yice with 10ft jaw. or eu.Mooned w,lh WOOden blocks. t.\cIurrt the hone In the drill malor, ~ the al.,.,.. and In..., 1"- non. Into lila cylinder ThorougtIy lub!'IcaIe IN C)tncIIr. ItW1I1n1 Dr! the
~ III I paca....n.;n proo:U;:w a flna ~ h*fl patient on !he cyIndsr .... wrth \he iii".,m.....:ting al an angle 01 IpPr<:Iximately 110 a..gr-. Be . . . to ..... piInty oIlubricanI and do nol off any mora ""'Iarlal than ill 0ICaSSIIry 10 produce 1"- dMired etIect. 00 oat withdraw the hone from \he cyt.... while ~ Is stilt 1t.n1ing. Switch 011 \he drill and contIoi.M 10 move H '-\? end down In the cyIirIder until ~ hal Itopped iU'nIng. lIMn c:orropra. IN star-. .-.d wIItaaw the hone. WIpa the oil ""'" the C)'fIndw and ~ IN ~ on IN oct.. cylinder. RoImarnber. do not taka too much mat.w from !he cyIndsr MI.

Is""

Engine, clutch and transmission 2- 27

'''. I 6b .. _making SlJre thol 'UP' marl< (arrowed) reeds corr.ctly 13 Wash 11>8 cyIOr>der!Ilhorough/y with warm soapy water to remove al l trac ... 0 1 t he abraslve g~1 Pfoduced during the honlr.g opeoII holes aod IIu8h Ihem with fI.IO!lir>g watfll'. Ahet rinsing. dry 11>8 cyIOnders thoroughly and IIPPII' a thin com of Ilg/rt. rust-prevemativa oil to all machined surfac .... ~ you do not have the equipment 0< desire 10 perform the honing operation. take Ihe block to a Yamaha d&alet or specialist O'I'Ol0tCyC!e repair sIlo!l.

1..

Installation 15 Check the cond~ion of th .. O-rings fitted around IhfI ba5e of each cylinder aod repIao!I Ihem wjth new ones If necassary. Check that the ma~ng aurlaces of the cytlroder block and crankc ..... a, .. tree from 01 1 or piecH of old

......

18 If removed, f ll

th .. dowels InlO thol

crank"""" (see Illustration). Ramove the rags from around the pistons. Lay th .. new bas .. ft&Sket in place on the crankcase. making sure I he 'UP ' marl< faces UP. 1\ locates correctly over thol dowels and aH "'" _ ...... correctly a l ~ned (H e Ill ustration) . Never ",-use the

~-. 11 " requirad, install piston ring clamps onto tI>e pistons to ease thW ..wy into the bores as "'" block Is Iowerad . Th" i, not """"t~ as each cytioolll' has a good Iead-'" Mabling the piston rings to be hand-fad into "'" bore. If possible. have an assistant to support the block wtNle this Is

.son..

14. t ~ Csrefulty I&ed the rings In USln9 " screwdriver and/or fingernail s F~ a new O-rtng onto eech .00 01 the coolant pipe. '""" pr8Sa the pipe Into the wster po..onp snd Inlet union simultaneously until the O - ~ngs "'" lei! to k>cat... msta~ the pipe boll soo tighten ~ securely tsee IIltJsl , . tion 22 InstaH the cyMnder head (see Section t t).

' '.21.

18 Lubricat.. 11>8 cyIindIII' !>ores. pIStons and piston rings. and the oonnectIng rod big- and small ....-.ds. with clean

""II''''' oi" theIl instaD th...tuds untol t he

th. block down OV .. , upparmo$I piston crowns m into the bores. AI this .tage lead the cam chain UP through the block aoo secUre II In pl_ with a ~ .. of wire to prllV8llt ~ /rom f ailing back down 19 Gllntly push down on the cytioo .... block. making SU ,e th .. pistons lint.... the bot" squarely iIIld do noiliol coeked $ldeways. if piston ' Ing clamps ara not l>aing used, cerefuIIy compra!IS _ feed each ring into the bora as the block Is ""-'ad (see IlIUlInIUon) . " neoessae block appallrS to be $luck IS Ih.. pistons and/or rings will be damag..:!. II c lamps ar.. uSad. remove them once the pistons are in the bore. 20 WI>M tI>e pistons ..... 00f'\'$CI1y \n3tallf!d in the cylinders. preas the block down onto the base gasket, ""'kOng ~ k>cat" e<>rractly onto tI>e doweb 21 II removed, Insta ~ the coolant inOll ""ion lISlng new O-rings and tight..., "'" bolts to the torqu .. satting specilied at tha beginning 01 Ihe Chapt"r. not forgetting t h.. carburettor breather hose clamp w here fitted. Attach the 011 000,,", hose and secure rt wItIl "'" "amp.

foroe"

au,..

15 Pistonsremoval, inspectioo and installation Note: TIla plsfons can be remoll9d will! fhe WIgine IrI !he frame.

Remo val 1 FIemovfo the cylinder block (see Section '''). 2 Belore removing tI>e piston from the 00IY"r!IClirlQ rod, &'ld HrKII ah'eaay Qooe, SlI.Iff a clean rag Into th8 hole arouoo the rod to or-tt the cirdip8 ot anyItoing _ from failing Into the crankcase. Use a sharp scriber ot fait mark« pen to write the cytnder Identity on the crown of each piston (ot on the inside of the skirt 1I Ih8 pisl on Is dirty aoo going to be clea.-l) as ~ must be installed In ~s original cytinder. Each pillion ohoUd also hive /WI ..ow on Its crown wNch ohoUd point to the exhaust (front) side of the bora 1_ illustration), II this ia not visible. mark the pisl on acoordlngly so that h can be installed the CO
2

2 - 28 Engine. clutch and transmission

"'1""

15,5 R~ the rings u .. ng a ring _vallO'(! insr.llatlon 1001

15.l1 M.k....... tIM oiI..,tum holM 1......-j ..... dIa.

01'- cltcllp and discltrd IMIn .. oew ones mUll be uMd. Wh«I !he pist"" "" bMn rwnoved. 1nI\IIIIIt. pn beck into It. borto 80 tn.t rwlMlId .,.,. do I'd gel muted up. RoIMe th. cr ......... n .., thai thfI best .,een '_lorloliChpillon.

c..uy noll whio;:tl wrt up ..a. .-..g Itt. and

= = •

HI

""'.ce

1/,.

I"IOt. u _ .ny circumetaRCeS. uSI • bruilh mounled In • drill motor 10 remo.,.. ~ from me plslOf>S; \he piston rnat.-llll 1• ..,It .nd wil l be eroded away tly Ih' wire

ffap;stonplnls.rJgIrlflfkl

lhepia:tonbo-.toak.~

n.tKl/lilgWllhN"ft'lenlrl'lrlgn

wn

~"'. 7 UN I plslon ring groo ..... elIan"", tool to .~ any coorbon deposits lrom Ih' rtng gf"OO,,". II • 1001 I. not Iyallatlla. I pte.ca broQn oft .. old ring will do !hi lob. Be "*y carel .... to _ oonIy till carbon ~ •. . . . . - any metal an::I do not nick

0<11 and ...11tP It around th. p.ton _ tIrOI .... ~ /he aJ#ay piston

Do I'd

III fI'1p "" /he pht. /I '''' pltlon P;II Is parl}cu/arly " .. bbom, "'Tacl II using. dr....boI. 1_. bul ba ,..,..,..1 to prol..:1 Ih'

., 0.- 1M

",me"",/y '0 ,..,. ._

pl8ton·, ~ surl--.

In.pedlon 'I

In which ~ .. 1liiy ......., be Inst-.:t In Ihw orIgloll ~Ion& If boling 1"1HISed. The upper of a.ach ring should hIv• • ~."*,,or_ ..... __ ., ..A_ _ _ of_ c:a1>on !ram 01 theScnipe piI\cnI. __ _blopl or • pioooI

01 ,..,. ...,..-y doCh ca"I be used ""'" ..... t 01 lhe ~". hlv, beoen scraped .way. 00

,*,on pIoI. 711,. ...111 tr.,p /he cJrcNp ff /I -"'II' oul.

HI

'"*

To ",...,..", Ih' clrc/Ip from p/I!gIng ....IIY. JUlU , rod 01'

~._diMMtar ,. " ...,... Ihan 1/,. gap "'"......, I,.. cll'f'Np and" Ihrough

•

, 5.11 M...... thI pillon ring-to-groov, cJHra_ with • ~II!II

S.!o.. tha Inlpactlon ptoces. Cln be

c.m.d oul. lhe pis!QnS .....1 be ~ and

"'""""..........all.

tho> old P"olon S u.Ing)'OW" IhI.wnt.. or • pistoo .-..g rertIO"4Ii Ind I"",nllion 1001, carefully ~ Ihe rings from the pistons 1_ lII>.1slrltionj . Do not nicIt or ~ the poS\CIIW in the ~

or

~1I"II..,..0I1I"II.-..g~ ~. have beoen ~, c:IMn till platona with IOIvMI and drt u-oughly. II thI Identification PfIVious/y ~ on b pIaIon .. "'->ad off. IlIo . . . 10 ,..""'" 1\ with b ccmoct idanti!y. Mag ....... \III 011 tit ..... holM below II>ft oil ring gt<><>'\Ii1

"*"

.... cIIIr 1_ MlwltnmonI. g C."I\l11y Inlpact each pislon lor CftICki ,round thfIlIkIrI, at the pin boos.- and.t the ring landl. Normll IIlston w... al>l>ll" II .......,. ywtlcal WIlt on In. thNal surf...:. 01 thI piston and alight _ _ 01 \III 109 ring In ~~. W1l"ll1kirt .. 8COO"Id orlC:Ull«l. lhe -'!line may have been sulfaring !.om ......tIllIng and/or abnormll combu.tie>n,

In •• ceasi....-ly high operlt'ng ltmparatu.... n.. oil t>Umll Ihoulcl be dl..:kad 1IIoroughIy. Also cr-k thaI the

..... n'ng

Qfdp ~ . . notdlmllgad. 10 A thI ~on c:rown. ....._ 110 be ...... '- .... indicatiOn thlt ,br\o.I.ua!ly I'IkIanca 01 apark I<noc:I! ldetonation). II any Of !hi probl ......

nc. ...

.boY,

,.111. tn. CII ..... mull be corrected or lhe d..-nagI will occur

11 M"a"",,,

~.

IhI

I'Islon

rlng·lo·g.oo .....

cl.... _ t>y la11ng ..eh pi.ton ring In I" ~ ..-.d eIippIng a IeaIer lil\iiii In ~ ~

I.... JII .. II"lion). Mak, sure you h.v, lhe c:orr..::t .-..g lor tt. groove {_ Step 5}. ChIck b-...call_orl....-locIIIIDr-.~

tIM g'OO're. II the cia.,..... " gtNt. ,"'"

IJ>I(:IfIad. ___ both bps!<>ll and rIngoo II • _ . II naw rings . . i:>IIn!I USId. " - " " IhI -....c. .... ng !hi rMW rIngI. II the

cIMrInca '- W-t. th;ln thaI &pIC1"-1, the piltOn II worn II"Id .....-I be ...--lId. 1:l Check the PlSlon-IO-bon> clNranc:. tIy

.........w.g

the borto (_ $action 14).nd the pili"" d'.",.,' .... Mal<. lu" each pili"" II malChld 10 It. correct cylinder. MeHUfl1I\I piston 3.5 mm (VZF75OR II1I(I Sf') or 3.0 nvn (yZFtOOOR) up from lhe bottom 0 1 the .k," and at 90" 10 Ih. plSlon pin Ixll I....

JIIul1.llIon). SuDtrac1 Ih" PIston dilmet ... 1M bore dia",.,t .... to obilin lhe ......anc:.. If n .. W-I .. lhan lh1 .pec,1Iad 1lgIn. the ,*,on be r.-.d \III1mr9 from

m.IIt

" " bon> itMllll w;1!!In lOmita. 0IhIfw1M the ~ be rat>onod). 13 ~ _ angina oil to tIIIlHlon 1"".

'*"*.....-1

~ Into !he piflon and chad< for .ny frttplay bItwaan the two 1_ M"'-trItionJ MNIUfI!hI pin ..terna! doamet •. and l1"li pin bon> ir"I 1M post"" t_ III"""U_I CIIc:u!IoI, b ct
InIIfI

pln·'o·plllon pin bot, ckwt.anc,. ComPW' ,he rasun to tIM sptCllic"lon. " the t>tglnning 01 me Chapl.... If lhe c .... aoce It

15.12 M ea-. the piston IIIarnat. with. the apac:ifIId cM_ ~ the bonom of tIM akirt

~at

15.131 IIIIp the pin W Into till piston (8) IO'(! \Jy 10 rock II back and forth.. II It'. 100M, .-..- till piston """ !'In

gr ....l« IIw1 IlplClfiad.......... IIle compOOlnlS Ihl t a" wom be10nd Ih"'. apaclflad Ilmlll R~I "" c/laCka I>etWMfl the pin and me ~ rod.".... end t_ SectIon 21).

1'1 Rln-.the ' - .......-:1 oil IN-Ihrt . . . puah-lit 1_ 1IIustraIlonj.

o.scaro IItIoIt

Engine, clutch and transmission 2' 29

......

15.13b - - . \ h e • ........,ldlll"""..-oI

0-IrgI .. JWW .......... t......:I.

.w.rr .,., blow

"*"

and

~

\he

them I»ck 1010 \he crtonkcase.

~

In.t.lI.tlon 15 l"'I*'t and 1",,",11 !he piston ~ (1M s.ction 16). " lucnc.t. the plslon pin. t". p/$ton pi" bore...cl !he connecting rod smaII-«od bore

ae..

with engu>II ail. 11 I~. new dn;IIp In the ...... _

01 the pislOO (do not l"e-llH old clrdlps). Une up the pIs\Otl on Its correct COtlI"IICIing rod. making aY ... the arrOW On In. pilton crown pointl rorw.oa!IN illustmlon 15..2)• ...:1"-' ItooI piston pin from !he other .ode 1_ tnu'tretlon 15..3b\. s.c.... \he pin wilh Ihe otllet new ,"-clip 1_ lIIu,tratlon). When QtaIing the circIipI:. ~ Ihem only juel enough 10 !It them In Ih. plalon. and mlkl .... lhey property ..-ted In their gro
,.

~

w.

lhecylndolr tlb:i< Ie. Sect;an 14).

18 PIston ringsInspection and InstallatiOn

1 It .. good jII'actiCIIO_the pIslon ringI when ..., II"IQMW ill being _uIecI. Before OIIIaIIing the . - pINon ringa. the ring end ~ rnuR t.. c:hect«
.. the cyIndoIr.

t5.t4 Pullthelwoolljetsot/lol'the _k_~

bore In the pillon

Ihtough. "*'II . . W.....a.ble. 10 -..eltwy .... not bIockKi. "",, e new O·t1ng onlO Neh t-t jets .,

~

15.13<: • . end\heInt ...... IIie
the new ring Mta !he ..... wi. t.. _tchld w;th the same pillon and cylinder d""'no the end Q-AP

2 Lay cut !he ptSlonI _ 10

-,..

......'.·$I',.nl

ptOCKl~"

and

engine

:I Tol"r1MSl..O"8 the tM 1_ _. tIon). 4 II the gap ill '-oer Of ......... !hen ~. dOuble dwdr. 10 mike .... that )'
conect rrogs belen

~

5" the gap 111100 ....... M must t.. ~

the nng _ . mey come in cont.cl WIth each cth..- dufing ~I .... op!!flI.tion. whlc;:h can ca.- &«ious d8lllaQ8. The end gap can t.. IIICfIlISed by IIlIng the ring end, very ~ with I fine Ne. ~ 1*101T"rWlg thII ~elion. lite only from the cutslde In 1_

Of

1Iustntttion1. • Excess end gap " not Cltttcai un .... it • Xceed. \he I8I"'IIcI limit. AQain. doubledwdr. 10 make ...... you have !hoi conect rings tor your and check !!\at \he bore iii no!

-

eng"'"

1 ReJ-I the prOOIdure tor IIICh ring that will t.. lnIIalied In \he qIIndera. When d"«idng the 01 ring. onIy!he1llde-reill can t.. c:hect«ould cont"'" each other. R......"ber 10 kllloP the fIngs. pistons ...cl cyIinderI matched up.

-

t5.t7 00 not _-compress the cirelliend milk ....... tI>ey _lin the groove

....-

• One. lhe ring end gaps "'''' been _~. the moo cen be ..... '*"'<1 on !he p;.!onI. 9 The 011 corrIn>I ring (lowest on the pilton) is Insta/led first. It is composed 01 ihr" _ _Ie camponenll. nam~y lhe e xpander end th. upper IUId tow.- MIe raib. Slip the ~ Into the groove. !hen Install the upper -'de ,.. 1_ ill .... tnotlon\ Do not \1M, piston ring Instlllatl:Jfl tool on the 001 ring .Ide , ...... Itwy ""'Y t.. damaged. Instead. pI..:e one end ollhe sid. rail Into IhII g.oo •• belw"n the ",pendef" and the ring land (SM IUu,trellonl Hold ~ fioTn/)' In pI..:e ...cl slOde ,I'ngtr wound lhe plstOO1 wtlli. pu~lng lhe raol Into the groovw. Next. inII8I the tow.- _ .... In !he same m ....... Mlk. aY'. the end. 01 lhe __ de>_....-Iap.

to

An ... the ~ 011 ring
~

......

16..9lI InateII the 011 ring

.~ In

lUI

2

2- 30 Engine, clutch and transmission

'

~ 2f!0

~.

215 0

215"

(!)

1&'14

~

I

the ypper and kl_ sIcM . . . c.n t.. II.Iff*1 _I ntyintlleriro;l~.

11 ",. Uppef surl_ of nen eomprlSslon ring IhovkI "-"e a matlt 01 lett.. II one end ...nic:tI must lace up IAIhen the ring it Inst.lled on !he plttan. 12: FlI!he ~ riro;IlnIo the rrkIdIe grD<>Ve In 1M piaIon. 00 not ""I*'d 1M MIl .-.y """" Itlan II neeenary 10 lIIide It Into 1>1_. To ,void brNking the ring. lIM e pialon tIng

IIP"d

braelcel 1_ Illull.ellon) . un the coyw _.,. from 1M engine, being prfIJ*'" 10 Clleh any rMlduel 011 which may t.. ............ IhoI_ • ........,.,..,. 4 Rernoo..!hI gaobt _ ...,.,.., It. NoM IhoI Idlu,'.

@

thooling oond a- .. thown

Top rtIg

."""""'' '

2 L..-oIrlng"'" 3 Upper 01 rlng s/dIt rei

18.12 Old piecH of feeIer!PU9fl blade can t.. u _ 10 guide !hi ring 0 ....... the phllon II'IOI:IM noting lhe position oIlhe klie

(!)

~ 01 1M lWO IoCItL
~ if they .... 1ooM. S WorIdng In " crIA-<:roa pattern. gr1IduII'f llacken lhe clutch ~ boItI unt~ spring'

_

.. ill .-....- ( _ Mluotrltlonl)

Inst.U.tlon tool I _ Iflu.t.ellon 15.51. or pIecn of old 10,,,1... gluQtl blld.. I _ IltustrMlor1l. 13 Flnlny. In~tan lhe lOP ring In the same rnannw Into !he lOp ~ In !hoi pI!Iton. ,. Onc:. the ringll Ire eOlTltelty Inflalled. o::t...::k they ...,... hel,. wImouI I/'oI(/giOg rod II"",,*" !heir end gaps .. shown ( _

.....

...".

Note: Tile elurch cln be ,.moved wlrh /lle engJlIOI 111 /lle frame. " rile engJlIOI hu been 1IIrfIOWd, ignc:n /he SNpt oo1IIdI
Removal 1 ~!hI_hInIg rod !hIrigtrt-hlnd fairing IIde paoeI ISM Chapter I). 0reIn II>e ..... a.I_Chapt.. n 2 On YZFHIOOR models, , . , _ IIIe Idle

1IP"d.,;lfus'" ffom itI_. 3 Woticlng ""enly In • " .....·e'o.. pattern, unter1M' ttle eiulch cover bolte, on VZFI000R

'--...-I

2

~plel.

nvu" WMI!er

""""-

17.&1 Clutchco _ _ ts

7 Loe/Iw.wI Frlt;t/onpor.teIII II PIIi'Ip/lltelil IOClulch_ II 0uIw Itwust ~te 12 CIuIch ho
" .... ,,-

13 NHdIIJ btMring

IS,"*"/IIovslplate

170i11UiIJ II""""q6-xfIr

Engine,

17.!it> Unscrew tIM clutch pra-5$lJre pial.

bolt,

a, described

17.5c ThtI pustorod can be witlldmwn Irom

clut ch

and transmission 2- 31

17.6 Draw 0 " tIM c lutch pial"

as a pack

tIM IefI

COUOI....·hoId Itle clulcll hous;"II to pre.....,111 turning. RamoV9 the bolt, and ~s. Ihen r""""", the clutch pressure plate. RemoV9ltJe pllShrod end-poece from e,ther the preaaure plate or the &halt. notIng Ihe thrust washer and baarlng 1_ iltuslrationa 17.27c and b) Discard the O-ring on !he end-pjece 8$ .. new

one must be used. H requlreod also rtmOV9 lhe ball bearing and puShrod from inside lhe shaft - you may need .. m agnet or magne t,sed

screwd river to draw them out (.... Illustration 17.27al. Otherwise. remove the front sproc~et eover (see Cha pter 6). lhen push the rod Into the .... g,n. from Ihe letthand side until the ball bearing coma oul of the rlghl·hand end of the shaft. then withdrew Ihe puahrod from the lell-hand aide (se. llluatration). 6 Grasp lhe compIele set of du1ch plates and remove them a s a pack (588 Illus tration).

Unless the plates ate beOng raplaeed with new onat. k .... p Ihem in their orig inal order . On VZFtOOOR models. note the notch In !he <;l.IIer Inctlon plate - ,\ IS supposed 10 be therlt. 7 Bend back the labs 011 the clutch nut i<>ckwaaha> ( _ Inuatration) To remove the dutch nul !he tnorlIIITIisINolnput !thaft must be locked . ThIs can be dc>r-.In several ways.. tI !he .... gine ~ in the frame. eogag.8 1St l;I8a, and haVfl an hold the . - brake 00 hanj w,lh the ' ... tyre In flnn contact with the ground. Alternalillely, !he Yamaha service 1001 (PI. NO. 90890-0(086). or e similarcornrnetdaly _ _ orl'lOme-mildottool t- Tool tip), C8J1 be used 10 slop the clutch oenlnl from turning whilst the nut 15 slackened. Unscrew the nul and ........"."e the IocI<.washer from the inpuT

_tam

shaft. ""ling how ~ !Its ( _ Illus trationsj. a..c..d the 1ooI<washer. _ a ' - one must bot

'7_~

W

used 00 1nsIaII8tion.

8 Remove the clulch Centre and the Outer thrust plata from the shaft ( _ IUustrations ).

",,---· L ~"'

'001 ......"" .."' _" g'Cl.U" " t>, " ~ lI . ..

A dutch cent,. holding 100/ C8I1 8IJSiJy be made u$/ng two slllp.s of . laeI with t". ends over, and bolted ~trnJr In ilia middle

bent

•

11.88 Slide the c lutch c.nt"larrow""l off tIM sl>8f1: .

2

2- 32 Engine, clutch and transmission

II Support the clulch housing and w~hdraw the large from Its CfIOI .... To get. II'\? on 1M ........ grasp the rKluIing and wiggle H OUI and In _ H should dnlw ItMo ....... OUI far «oough to grip H. Wdilllculty" ~ In oettu>Il.grlponthe ....... InNI.~ bolt nlO _ or both 01 'hi IhrHcMd holes and pull the ....... from I'" r.ou .. ng t_

.Ieev.

-I.

10 Wlththw the caged MedIe rot. bNMg frem ItMo housing If H dido't come • .......,. with ,,,. ......... and U- rfImOYfIthe I'IoOI.oIjng from ,,,. engine. not ing how It eno.g" wllh Ihe

primary drl ... lIIIar arid ,,,. 011 pump driven

o-r (_ Iliullnltion). 11 R _

t'" /nnw thl'\lll poIlle from the

Ihart(_~.

Inspection 12 All ... an • • t _ period of..vlce thl clUlch friction ptales wdl _ and promole

clUlCh slip. MelSure Ihe 'hic~nass 01 .ach I~C li CH'l plete uslno • IIflrnl .... caliper t_ Illustnol!on). II any pate hu worn to or beyond the urvIce IImH glYfln In 'hi SpecII\caIIoM al tlla beg,1'O'IIOg 01 'lla ChapW. the ~ plate. n.a be rerwwtICI _ ...... AlIa. M...., 0/ the plate. IImII: tum or . . gIaad.lN)t ....... be ....-.d _ a ..... 13 ~ pl,at.. IhouId not .now eny signl 01 •• c.u huting (bluing). CIIfIcI( lor warpage ualng • Ilat furfllCe and I......

n..

DI"JD"I1_ MI",~).llany~ta",,~

the

m•• lmum permissible amount 01 w~. or IhOwt signs 01 bluing. ell pIIIln

plates .....tbe~ua_ . 14 M ....... the If. . length of MCh clulch

apnng using a -"ifIf' caliper t_ 1IusttrionI· W...., IIPfW'II ill bIkIw the....w;. 1ImiI~,_ .. thellP"'9_'''''' 15 npect the cIUIch ~ lor 1;Io.Irq.-.d indentltloM on the edges 01 tha protruding tangs 01 the Irietlon pIataa IIndIor aIoIIln the

edge 01 the

houainV with

which !hay ~.

Simllarty ch.ck for wear belWHf\ tile Inner tonguN of the plain and the 1IIoC. In the clutch <*Ilrl. W. .r of thill nat"", will Gausa clutch drag .-.d aIow ~ during o-r cI'owIgII_ the' plat. wII snag ~ the' pre$$I.K. plata .. lifted With care a ....... _ 0/ _ can be oorrect.cI bV dt.-Ing

pia""

wi1h. h Nt, but" thiII ............ the cornpon..-rtt IIhouId be _ . 17.1 t •.. Irld tIM In ..... thrulJl pili. ,~-

worn

15 InIj)«! tha ........ and caged..-dll roIIr blaring In <:onjunc:llon with Ihi cMch Musing'1 Inllmlll bestlng au~_. If tIliII1Il1rf1

any signs of _ . pitting or o1hef damage lila affected parts """,t be renewed. 17 Choock the ptWII.II'e plllta and I~ bearing 100" sig .... of _ 00" damagI and rouotw-s. ChIcIt ItMo pueIVt>CIend pac. .rid ball t...Ing tor signs 01 .ougru..... _ or dII~ Rep..:. ..,v part8 •• -....-,. With " -

-

1 8 n. cIUIch ....... mect\aonIIm. ~ II the Ifonl &pI'OCluId be also be

cMd<ed ( _ $.,;tIon 18).

18 Check that the push.ad II straight by .oIIing Hon a IIDt surfac. - ~ II ill bent by mono !han !hoi runoot ImH ~, replace H with a n.ew one. Chec~ 'lla pushtad 001 .... lor -'!:Ina oIl1oakag1lnd repIeoIM with • " - ona If ~ry, To raplace it. fl ..' ..........e the /runt spmcl<et ~ (1/ no! -....tv dona ~ _ Chap!« 6). l _ out thl old _ using • acrewdrfver. AppI)o gtNM to lha ~pt. of the new seal. ttlan drIvto II ~ Into place

-.. In,t.1I

the

'.ont

Ifl"OCkfII

cov...

1_

Installation 2D Remove all trac.I oj old gaslllII from the ~..-.d cIu1ch COY..- surfaca 21 Slide tt. Inner tm..t plate onlO tt. IINI'I. 1_~I7.I1)

22 l1IbrIeatl the ...-.die toler belling and ........ with ~ ~ 01. tnstaIthe cIUIch houWog. without ill nMdIe roller beM'Ig ..-.d _ . and .upport Hin pDIIition, making ......

M it M>O"CI'd COf'I'KIIy with the primary ~ DfIIf on thl <:rankshafl 1M. Nlustr.tion 17. 10).

Engine, clutch and transmission 2- 33

\•

i

•

D pl."

17.2ib FIt. fric1Ion first tMn I plain plate and ... on

23 Install 1M _ . with Ita bolt _

r.cing

moOd.

OUl,...cI 1M ~ ~ WeI the of 1M dutcflllOualog ( _ i/Il",lrallon5) . 24 l.JDIc;Iot. 1M QO.IW thruIIl p111111 with o;IIIIn tonglne 011 Itld lit It onlO IN ah31t , ....

"'_,7...).

SIicIa 1M

~

and thrust washer onto the

IInd-piaoa (HIllh..lnltion.I. 28 1""dlM press!II'I pIIIt. onlO the cMctl, .rognng IN clot on \Ill piall WIth the one on It. ~ _ _ 1_ ....Ir.tion). Install It.

17.2IIt> On VZF1000A modele. •• I",n the (I) with the......t
nol~ btl

_

.nown

-.Iv

~....:I !hi t:lo"- and tighten IIwn In I crla.·e
"ttllIII (... Illustration 1T.5b)

Ccunt ...·hoId the dutch hauling to pr....-.t " norrq wIwn \9rt1rWl!l It.Ipring boIII.

25 Install IN clutch ClOt •• onlO IhI analt aph.-{ .... lIIu.I.Rion 17.a.). Ihen 1.,.1.11 Ih. new l oc~waaher . ..,glglno II. tabf, Wllh till slots ,.... 111..atnolion) 1.... ,l1li the ckJtch nul and. u""'ll Ihi method IIT\pIoy«I on fIM<MII to lock IN input wit 1_ 51.., n. 1Igh1., 1M nut to 1M torqlII MIUn!I tpeCIfIId at Ih. bI!I,mllng 01 th. Chapter I'"

2

Illu.t.3tJon 17.Th). Notl: Check Il0.l1 1M

c.\!tch CItIlfi ttllita rraeJy an.r I!QIIlenmg. Berd up tIw tebIo olIN ~ to IIClO'tI tIw nut , _ -...nllonl. 2tI Coat..:h clutch plata with engine oij prior to inslal13tion. Build up tIw pIIIl. as ,_ : fQI !II • friction pIIIt •• thin • plain plaCe. thin altlmllle friction ...:I plain pIIIw until .. WI

_ _ ,~"'IMoo.n.r·mosl IrIctlon pia" .. tIw one with • notch In one d its tabI. IIIgnng thaI tab _ \Ill mar1<ed Ia"ogI on IN clutch ~ 1_ "",-"aIIon.). 27 Fit. new O-ring onlO IN pullJvod lind· _ . lubnc," thl thtvsl bNrIng and W _ . 1M puaiwod ...:I.piaea. O-ring. ball bItIMg ...cI pueIYod with IIIghtwaighI lithium IOIP based gfUH. Slide tN pushrod inlO 1M ahlIft so !NIl III rounded _ t.c:eo IN left· aide - II IhI sprocket C(WII' has b..-. _ _ ~ can be ~ad """' 1t.1IfI·1>Ir'Id ,Ida ( _ 111".tr. .on 17.51:1 Fit !hi blIli bMo1ng ...cI the _.pa.::. (HI MlustmIon.).

""lid

17.2Jb . • and the end·piecl.

2- 34 Engine. clutch and transmission

Inatall ti'le clutch COYer USI"II a MW ;ukat

and tighten It, bolt, .... enly In a crl..·crou MqVIIIIOII to the 111*'''*:1 torq~ eet1lng (_

18 Clutch relNse mechanism removal. ovtHtlaoi and installahon

::;. ~

~

m... tration) .

30 Ref.the ~ with 011 (_ Chap\« 1). 3t Instal tIIII '--1w1r.g and \he Ianng aide . , . . . . _ ChIpt. 81.

Maste,. cyllnde"

.r.

cyIindef ov.m.uIla~, 2 IIef
~)~

DOT.l"rydralAIctnM_cIlitdllluld.-.... WId ntemaI circIIp pIIetIt. r.tot.: To ."....",,1 damage 10 1M pJMt from IP'liffd tx_k. nu/d, always COve. 1M ru./ tank_nd

c-.,..

fa/ting"",*, ~ on !/Ie mIISf8rq.tnder, Call!lon, Dl. .... mb/y, overll.ul and

!ii~'

d*

.t. .

1 It tI'Ie mall!. cyIInd.- is INklng 1Iuid. '" II tIIII clutch doea not work property when tIIII lever II ~ . ..-.:I bleeding the doea not help ( _ s.ction 19). ancIthe hydraulic h""",,, Iii In good concllllon. tn.n maIIt«

_'.uly

~ ot 1M mas'... """"""""" be clean w<>t* _ 10

done In •

_CO/Ir~and~''''''01

tl>al!y
RetllOVal

'em<)""

',,~

3 On VZF750A and SP model •• tile ...voir ~ "*"P and pertIa~ .....-.-... tria cap ( . - ....... tion). On YUtOOOA madill. toc:.arI. buI do no! remove. !he_1lOIding tIIII _ _

In~

t--.....uon)

.

18.2 Clu'tch ....... rnecI\anIsm cOrnpo
_ ...... -.

"..

-.-~ Plsl\:ltl~and~

""'"

.. PuaI"Itod and bush

--

""'" ,-

lOOust . . .

1~

ReM
II"IOUfKIng bolt (8). and '-to I.rion (C). and cIutdI ' - banjo bolt 101~

and Sf> mocIaII

Engine, clutch and transmission 2-35

• Disconnect the clutch switch w iring connect", ,see Illu stration). ,,_ov, 1"clutch _ (_ Chapter 6). Take care not to lose the pushrod bush from ~s socket in the

"-

~ Unscrew the clutch hose banjo bolt and separate the hose Irom the ma.lbI cylinder, noting the alignment (. _a IIlu.lrallon). Discard the sealing washer$ as !hey mUSI be replaced with new ones. Wrap the end of the ho... Tn a cfean 'ag and .uspend it In an upright position or bend down carefully and place the open end in a clean container. The object",. is 10 prfMInt alCC1I!I$1Iie loss of brake fi"id, fluid spill. and system comamlnaUon. 8 On VZF750R and SP ~., unsc ...... the bolt securing the reservoir 10 the bracket, ttleo release \he clamp securing the........,.. t..to th' union 00 t he master cyl inder ( ... e IlIUAtralioo 18.38). Remove the.-voir ClIIl and lift off the diaphragm plate and the ~

18,5 Clulch hose banjo bolt (arrowed)YZF1000R ..-Is

18.7 Master cylinder ct.mp bolts (arrow
diaphragm. Oraln the brake fluid from thtl ~ InIO a suttable co"'.lner, ttleo detach thtl "","""olr hose from ~s union on thtl master cylinder. Wipe any """""rMng fluid ouI of the .-voir wI\tI a c~ rag. 7 Unsc,ew \tIa masl .... cylinder clamp bo~ •• notl"" how th' 'UP' mark faces up and tha lop mating surfaCM of the clamp align with the ~ on the handlebar. then lift the master cylinder aWlly from t"- handlabar ( _ 111....tration). 8 On I'ZflOOOA rnOOeIs. "'"""'" the reservoir cover <9I8inng screws and lilt off the cover, the diaphragm ",ate and the ru~ diaphragm. Drain the brake lluld from lhe reservoir lnIo a suit"" container. WIpe any~ livid ouI 01 the .-voir wtth I clean rag 9 If required. remove til
ftllid '""""DO' tIoSoII union rubber cap. tI>8n _ t"- drc~p and detach the union lrom the master cylinder. Dtscard lhe O-rl"" as a new one must be usad. Inapact the .-voir hose for cracks or spWts..:l_ W.-sary. 14 Clean al l pan. wllh tift"" bl"aka fluid. II compre$Sed air Is available, use it 10 dry the pans Ihoroughly (make wre II', liltered and ...... lubricatad). Caution: Do not, IJndar ar>y cin:umSIat>Ces,

Chailtar 9). C,out/oll: Do nOI tip I/). m,o"lr cylinder upside down or fluid will run out. Overhaul

18.10 Draw the puShrod and the rubber bool out of the cyflnder

10 Draw tha pu,hrod out 01 thl master cylinder. noting how ~ k>catH In Ihe rubbe< bool - t"- bool may come away with the pushrod , ..... illustration). 11 If ~ dldn'l come with the pushtod. remove the rubbet boot from the end 01 !he pisloo in !he cylinder. 12 Using cll"(:lIp plla"', remove til
-"". 13

On

VZF750tl and SP models, remove the

use . petrolelJm-b,tsad solVent

10

clean

bnrlr_ptlrfs.

15 Check the maste, cylinder bore for corrosion. scratches. nicks and score marks. If dama~ or Wear Is evident, the maSler cylinder must be replaced with a new one. If the master cylinder ia io1 poor condition, lhen Ihe ,elease cylinder s.houkJ be checked as well. Check that !he fluid Inlet and ovtIe1 ports in !he master cylinder .... deer. 18 The <:1..ISI boot. QI'CIip. pistoo assembly and spmg lire 0>cUded ... the n!buIId kit. aI of the rlfIW perts, reoardless of the apparent condition of the old ones. If the Mal and ClIP lIr9 not oIready 00 the piston, fit them aocatIing to Ill01 turn Inaide out wher1 they are sl ipped Into the bore. Dejl
u...

2

2-36 Engine, clutch and transmission

18.29 Make stJrelhe diaphragm Is Installing the plate and c over or cap

cOlA"CtIy Hated bef......

Ig Insta ll the

dust bOot, making sure the lip is _lid correctly On the 9fOO"'I. 20 Nt the pustrod into the end 01 the master cylinder. making !lUre the rut>t.- boot kx:at"" In the groove (see Illus tration 18.10). II removed . I~ the puslvod buSI1 into the socket In tha clutch laver, then Install the levar. makir>g sure the pu5Ivod end kx:ates ,"10 the hole in the bu!lh ( _ Chap!.... 6. Section 5). 21 On Yl F750A a nd $P models. lit a new O·ring onto tha r8Servoir hose union. then pre$s the union Into the master cylinder and Meure it with the c"cllp. F" th_ rubber cap r:N«thecircttp. 22 Inspect the reS9<"Volr cover rubber diaphragm and renew II d amaged or ~

cIeIer\orated.

Installation 23 11 removed. Install the clutch switch (see Chapt.... 9). 24 Attach the master cylinder 10 the handlebar IWld Ii! the clamp with Its 'UP' mark laciog up. aligning the top mating surfaces 01 the clamp w~ h tile punchmarl< on the handlebar (... e illustration 18.n, Tlghten the upper bolt first. th"" the low... bolt to Ihe torque oetti ng spec/Iied 81 the begirri'Ig oIthe Cha¢er. 25 Conn...,t Ihe clutch hos.e to Ihe masler cylinder. using new sealing washers 011 each s ide 01 the union, and aligning Iha hose as noted on removal (se. lIIu.trallon 18.5 or 18.33). Toghten the baoio bolt to the torque s.etling specifi8d a t tha beginn ing 01 this

",,',.

26 On YZF750A Md SP models. mount the reservoir and tight..., tha I>olt Meurely (s. .

18.32 Clute" "0... b...,jo Illustration 18.301). Connect the """"""" hose 10 the ooion and """"" 1t with the clamp. Z1 COM...,I tha clutch switch wiring (see illustnotion 18.4). 28 Fi ll the fluid resarvoir with new DOT 4 clutch fluid as d HCr1b8d in Daily (pre· ride} cll&cb. Aefer to Section 19 01 thts Ch apt.... and bleed the alr from lhe system. 29 F~ the n.bber cIIapI"w"agm. makilg "'"' ~ Is correctly seated. the diaphrngm plate and the cover or cap 0010 the master cyIi1der r8S8!VOi" (see lllustrallon). On YZF75Of1 and $P rnodaIs. lit the cap clamp (see Mlustration 18.33).

30 Check the opef8.tion of the fronl brake before riding the motorcyCle

Release cylinder Removal 31 If required lor Improved IICCiOSS. remova the lower lalring (see Chaplet 8) 32 Hth& release cylindw is jus! being displaoed aod ~ completely r8l1""OCNad or owrt\aUed. do oot discoonect the clutch hose. Otherwl5e, unscrew the clutch hose banjo bott and separ\lte the hose from the release cyllndIIr. noting its IIIignmIInt ( _ lIIustmtion). Plug !hoi hose end or wrap a plastic baQ around ~ \0 mnimise fluid klss and prENent dirt entering the

system. Discard the sealing washers as new ones must be uSlld 011 inststlatien. Nole: If

you're p/fJnIinf1 ro ~!he release cyitIder &tid don~ a source 01 ~ air to blow out Ihl> pslOtl. ~ -">r:>SI(V1 !he '-'i<> boll .1 this stage end nl~1een be used ro boo the pislOtl wI of th6 body once tile cylinder h6s been

""WI

1lt!boJI«1. CIis<:onnecI !he IlOSIt """" tf>e pislOtl has ~ sufI'iciIr1tJy 6sp/;tIced.

33 Unscrew the thrllt! bolts securing the re lease cylinder to the sprocket COVer and remove the cyiindl>f (s e e illustratlona). Ratrieve the two dowels ~ they are loose. II required. withdraw tfle push rod. Do not operate the c lutch lav ... with the release

=

cylinder removed

•

HINT

"th_ ra/aase 15 not being. dlussembled, cylinder

11110

piston can be prevanl&<1 from cffHlping out of tI,a

t"1OIrtua cylJnder by re&fraining

it with

a

couple of C8bte tIN p8ned tllrougll tile mounting bolt 1IoIas.

Overhaul 34 Remove the dust _I from the cylinder. ooting how ~ fits (see Illustnollon). 35 Have a supply of clean mgs on hand, then pump the clutch laver to expel Ihe piston und .... hydraulic prusure. 1\ the hO" hao already been dalached. use a let of compressed 8;' dimctad inlo the tluld Inlet 10 expel the piStOl1. Waffling; Usa only low air p ressure, otllarwlsa tlla p llUm may be forelbly 8111'8/1&<1 causing I,.,jury. W,ltp file cylinder In a re g bef.". appIymg tlla air. 38 Remove the spring lrom the PlslOO (... e illustnotlonl8.41). 37 USIng a ~ a5tic or woodan tool, remove the piston $eal from the pi3ton groove (I . .

J.\ ili

Engine, clutch and transmission 2- 37 ....trMIonl o.e.n::I both _ on.IIt~..-d.

31 CIMn!hlI*lon _

--

hydraIk fluid.

with _

~

us. •

as .......

~

........ C)Inder bore

00 no!, IIIIMr ..., circumslM>cM, .oIVMt to cIoN"

"'lrMum.~a.d

311 IntpeCl lhe POllon .nd release cylinder bor, lor ~ of 1lOIT"OSlon. nk:Ioo and burrs .nd IoN of plSI'ng. II I ....rl_ delecta "'. lound. lhe pI.lon and cylinder shouk! ~ fep/ated with . - ~. ~ \he release cy!inder " In poor condition the mast. tyi....,... shook! eIso ~ overtIIIur.d (_ .oovOYe In \he poslon At It. ..,-ow ..-.d 01 !hi splog 0*" \he lug on the I....... end 01 the poslon 1_ iIIu.lf.tlonl Lut:n;.t, \he poSlon and ..., ""Ih clMn hydraulic IIuId and In-' the -..DIy Into It.~. lIM yox ttU'rbs 10 pr.a R ~ hto !hi C)Inder lnsteUIrtion

42 II ,.no"",. "'blle:.t. lhe pvsIv"od wtth I lighlweight Ilt~um IOIP based _ . ~de thl pUlh.od Into thl ao thaI Its loundlld ",d lacH Ih' lell·hand aide IHI

"'II""

Mlusb"1tion 11.!it1. 43 F~ the dowft Irl10 the aproc:ket if ........ovIICI. then Instan IhII . . . . C'j"WIder WId light'" the boll. to lhe to
eo_

w.--

IP'tIIIIICI torque ..II'ng 1_ ilustrallon 18.32). otS Remove IhI mIIIt... C'j"WIder .--voir ClIP or COY8I" .ond _ _ the diIp/IraQm plate and di&pI"ngm lHe lbove). Fi~ the """""""" wI1tl n.w hydr.ullc fluid lHe o.Jly (pre·ridoJ) cn.cb) lind bleed the Iystem "" drIscr!bIICIln IMICtlon t9. o-k for lluidleakl.

_""

19 Clutch -

<-

~

'"

, BIedng the dt.IIctlis ~ It. ~ of ......cMng .II the ... bubbIIIII fnIm IhrI master cylinder, the IIy!;QuIIC hoM and the ...... cylinder. BIeMI'ngl' _ .. ry ,""-,,er, clutch .yat.... hyd •• ulit connection i. 1ooMned. wtIef1 .. componenl or ho .. I. _ _ lid, or wh", lhe mUler cyllrtdef or cylinder I. ov"lIIulllCl. Leak. in the ayslem may 1110 allow aI< to enter. bulleaklng dutch IIuId wlQ r~ their PI''''''''''''' and warn you 01 the l-..:lior repair. 2 Tobleed IhI dutch. you wiI need some.DOT 4 br-'<e .nd cluCch 11Ud. alllnglh of clear vinyl or plastic: tubing .........11 cont_

.-.Ie,,,,

, ... 1 Fh

I*'IWt /IIIICI wI\tI clean 1Iuid. a supply 01 cieerl rIgII a'Id a to tit the ~ - . 3 Cover lhe fuel t."k ....:I other paintlld ~ to p " - " damage ... 1hrI-"

"*'"'"

dllphragm pilIl, and cap or cover. Wipe UP ."y spilled I'IuId end chrIck thaI tt.er. . . no IMIw !rom the IJyalem ~ lCIlYatlld Relit IhI _ ClIP over IhI bIaed Y1IIvL

u.tf\.lid.~.

4 PoeItIon!he bI<e 110 that !he . . - . cyInder ...... " " ' - IhI master ~ ~ C.IP or cov •. then f8f'I'ICMI the dl~m plate Mel di.Iptngm (Me SectIon 181. $lowly ~ the clutch ........ a lew limes .....u no .. bubblel can be IMn floating up Irom u.. botlom 01 the .--voIr. Doing thi' bIeIICIs .. !rom the .....1. cylinder end 01 the hose. cauflon: 00 nOI pump the Ie_ too quldrJy al nu/d could IpUff out 01 th. ~ and onto. painted component. !5 PIA the dlIsI ClIP oIIlhrI bleed va/w 00 lhe ,MeaN cyl,nd• •nd att.ch ontI end 01 the ~ tut>lng to lhe valve 1_ lIIuatrallon) . SuDrn<Wge lhe 01"- ....:I In IhrI ftulcl In thrl COtItalMr Check lhe nuid level in the .-voir Do not .now It 10 drop below the ~ """' cII.ftIg IhI bIaedO'>g proceM. 8 Pump the clutch ........ slowly three or to..I' ..... and hOld It In ~I lhe ltandlebar wtlllll opening the bIeIICI valve. When lhe vaw. " optlMod. fluid wla flow out of lhe . . . . c;yIlnc* Into IhI clear 1Ubing. 1 Tlght'" the bleed valve. Ihen relea.. thrl ~ graclUlfl)r. Ae\)eal the process until no air bubbl •• a .. vi,'bl. In the fluid leaving the rliNN cylinder, and Ihe clutch scHon I.... smooth and progrMSlv •. On completion, tight.., the bIeIICI valve 10 !he IDrQUII MIIlng specIIIed at IhI b.ogIn>ing of the Chapter. 8 EnIufe that 1 h I _ is I"""""up _ _ the low..- ....., marl<, Install the dlaphr'lgm.

NOIe:

n.. gea~ mec/IInlsm

can

~

""ma.

rwnoved with /he ""9;"" If! the "/he engl"., !'laS been ..moYftd. igoo .. tile ltep.o

which don'I~.

Remo.,., , Mlk, IUr. th. transmission I. In ...... ,..,. FIamoYe Iha lower laiMg and the lulng 8Ide pe,naiI (Me CI\apter 8). 2. Rern<we tha fronl sprocket t<>_ (IN Chapter 8). n-. " no naIICI to delech the clUlch r.tN", c;ytinder from lhe cover lIN

,....,'

..

3 RernoY.IhI cIuCct\ (_ Section t1). end W IhI Slopper arm a'Id MIIector dru:n . . bIOrIg removed •• 'ao remove tN 01 pump ( _

SectIOfl2t). 4 Slide the coIar ott the left·hIwld _ 01 the getUChange altaft, then "'""""" the E-dlp.nd the washer 1_ ",...trMIon) ~ Nole how the gearchanoe shaft cenlralJaing spring rdlliI on aach side 01",. Iocatlng pin

In the eating, and how lhe pawl. on 1111 ultclor arm locate onto the pins on IhII end of the M/eCtOr drum lIN MluoItrMIon 20.1 1) Grasp IhI _ 01 the ahart end ~ the 8hltttlerm .....-nbfy (1M iIIumation)

2

2- 38 Engine, clutch and transmission

IhIr lIappet .,.,., aptIng. Ih«o inltailthe ~. and the stapp. ann. locating tM Irm onto the -..traI detent on IhIr MIeetor drum and milking .... the aprIng ends ... po&itloned 00fT.,;;IIy 1_ llltatr.tlonsl. Tigh",!he boItI

to tIM torq.... Mtting speeHIed "I tM ~ 01 !he Chapter. 11 ~ lOme g<eaH to the 111M! of tM ~_oiI"""'InIMIeh·'-'d'"

0 1 the CfankclH. Slide tIM ,hslt InlO pliC • tIM wly through the CIM unto 1M splined end ~ ""'1M o!hcIr aide 1_ .".;I puIh II l1li

20.11 The In.talied ISHfI'IIIIy should be II ..,.."

II If '«11,11.40<1. not. how tM I tappet" ann tpMg ton
......

Inspect/on 7 Cheek tIM MleelOf' .rm 10f' crKkl. distortion .".;I _ 01 its and ct...:Ir. to. any llD<'fMPD'Iding _ on the !l(llee!or pm. on 1M Hleelor drum. AJso checI< the ,tappet .,..., ron. Ilnd the delllnn In the HIeciOf drum lor any wear or damage. and rnske sure the roller tuIraIiIIng ~_.

tpMg ~ pr. In the crankcaH Is ItICInIV 1IghMnMI. " It Is IoosI. _ it and ~ I non-~I

Its ttn.II,

II CMck

tt.r.1d IocI
tfwIlVrten •

~.

ge.archange Ihlll for 1M . . . . "1M IhIIt Is ~ you can attempt to straogI'IIen It. buill 1M spIInw _ denIegId the _ .....

tIM

SIIWgh_.".;I $mIoge to

be renewed. AlIa cheek Ihoo condition of the .".11 011 . . , In Ih. left-hand side of the CfankCSM. 1/ k I. darna~, det.no.-It..:t or ~ signs 01 teskag.e ~ mUlt be r&pllc..:t with I new one. Liver out the ok! H.I Ind ~ tIM MW ."... ~arety ~o pIacto, with its lip 'acing Inward. ullng a seal d~ve. or autllIbIe.acl<el.

Inatsllst/on 10 If NoI'IIOWd. Ipply " suitable nonpsrmanent tined locking compound to the Slappet ..." .".;I . _ ~. bolla. loCIte

Ul .... tr. lton 20.5) . Locste thl Mleetor Irm PlWIl onto the pins on the lIIIeeIor drum and the centralling spring ton
21 ON pumpremoval. inspectiOfi andiflStallatlOfi Note: The 0/1 pump can be ,.,...,....., ,..(fft the .ngI". In lhe mu".. If the errgi.,. ,.., 0Hn IWrIDI«f. tgnc.. the IMpS wNch don~ ~

Removal 1

Draonlhlr.ginotoil{_O\apI.'~

2 AemoYe!he dutch 1_ SeetIon IT}. :5 Tum the 011 pump driven gear to -'Ign IhI hOlM In ItMo gear with the pump mounting bolla 1_ IIuItmIonI 1 ~ ItMo boItI and withdraw !tool """'" from the r.ginot. being prepered to catch .-ry

''''dual al l I' •• 1I1 .... t •• tlonl. Disce.d ti'll 11'$1<11,'" MW """ fT>.J!Il be UMd. ~ the dowel from eithlr" the pump housing Of to. crsnkcaM W" lliooM ISH IIllIIu.tIorI).

InspectIon 21.3 01 pump bolt. Ierrowoodl - allogn the hoIH In tn. ""' wtth tn. bolts . . shown

21 .... WithcIrew tM pump ••.

a w~. the pump ca'I be '*-"bled lor cleaning and inspection. RomoVI the .tngIa.....,bIy acrew, Ih«o o..w 11M pump bodV. 1M out.- fOIor. a"ld to. !Mer rotor 011

Engine, clutch and transmission 2- 39 the drive shaft (see illus trations) . Note which wlJ'j rn<.<>d the I'Q\Q/'S lit and how the drive pin In Ihe sl>aft locates in the I lots in the Inner 'Olor. Remov. tM drive pin. t!>en slid .. the wasl>e< and pump <;ove, off Ihe s hall (_ illus tration). Remov .. the Ioc4tino pins Worn the cover lor saI~eepiog K they are I<.>ose. & CI....., all the components In sotveot. 7 In, pect the pump body and fOtorS for ICoriog and wea, (s. . illu s tration). If any damage. ocoring or """""" '" exoessive _ is evident. reptace lhe pump with a new one (lndlviduaj componeonts are not available). & Fh the ClOter rotor ""0 the pump bOOy. Ulit the inner rotor into the outer rot",_ Measure the cleerance betweao the outer rotor and the pump body with a I....... ga"ll" and oompare it to the mwcimum cl..",anoa listed In the s.pecifications at the begMiog Q! the Chapter (s. . Hlu$lJ'8tion). II the clearance measured is ITHter than the maximum m;tlld, reptace lhe pump with a fleW one. 9 Measu,e the c lea,aoee be\WllllO the Inne< rotor tip and the out .... rotor with a f.... l", gaUlle am! compare It to the mwc imum clnranoe listed in the specifications at the of the Chapt.... (... beginning Nlustration 21.81. Hthe clearance measured is ITHt .... than the ma.>
21.4b . .. and remove the gaskfltand

21.5a Remollfl th .. S<:l'ew .

dowel (arrowed)

_sary ~ H is intogrnl with !tie shalt. H the V9f"ywom. also checl< the drtv91)88f on the back Q! the clvtdl houaIno ~ if this too 1$ damaglld or worn beyond """,ice. a new housing must bII littlld. 11 If the pump Is good, make s ure sllth .. componenls are clelln, then lubricate them with f'I8W engine <>it. Fit the b;aliog pins Imo the cover n removed (He illustration 21 .5<:). Slkie the pump CQII1lI" followed by !he washer onto the shalt. then III the d~ve pin through the hole In the shaft (Me inl.lStrations 21 .5<:). Slide the inn .... rotor onlo the shaft, with lhe sl015 In the rol", facing down so that thfly OVlH" th.. d~v e pin (s •• locate illustration 21.51» . Frt the outer rotor onto !he gfIDI"l$

...

inner rotor. then fit the pump body over the outer 'otor ISH illus tration 21.Sb). Install the assembly SCrew and tighten it to the torque ""\tong 5pscililld at the bflg innlog 01 the Chapte< ISH Illustration 21 .5a1. 12 Rotate !he pump shaft by hand and check that the

rotors lum smoothly and freely. n not.

replace the pump with e new one. Selore Installing the pump, prime it by lililog it with

ctean IInQIna oil. Installation 13 II ,e movlld . tit the dowel into the pump body, thoo Irt a new gaskltl onto the pump, ma klog sura It locates ov,r lhe dowel (see illustration). ilJign the tab on the end 01 the

~~~~------~

• 21.51> .. . and draw the body IAI. outer rotor ( 011 the s hall

).

I end Inner ,otor (

2

21.5<: Re move lhe drlva pin (A). was her (B) end I""""ng pins (C) . then dra w the c o ..... 011 the shaft

B

21 ,7 Look for S<:Oring end wear. s ItCh as on this outer rotor

21.8 Me aaure ouler ,otor to body <:Iu ranc. (A) and Inner rotor tip to O\It....

21.138 Align the tab on the shaft (a rrowed)

rotor cte.aranee (B)

with the . 101 In the wat .... pump ..all

2-40 Engine, clutch and transmission

_I.

7 CIMn tI>e 01 .u.w- and _ In soIYant and_ln)'detwlacaughlln _ _

~ drI'4 IhaflIO IIWIt 1\ wII ~ WI) ~ Iiot ... ~ punp <101-4 nrt, thin qtIII

lhe pump, II'IIning til. IrT'OW on th. pump body _ IIWIt on !hoi orriCIM MId mMIng ,.". Ilia dowel loc.t.. COIfectly (... Illultratlon). Wiggle the gear II nICIU8f\I 10 IocIIII tM Ihatt end In Ille wit .. pump, Tum tile pump gear to .I'sIn!hol"-'" tile Q$II. wltI'I 1M pump mounting bolt r.ol.. (...

mesh. Inspect the 11'''1lII' 101

by blOwing them Ihrc>ugh with compressed

'"

IQI"""

Illult •• tlon 21.31. Apply • -..lIable non· compound to IhI

I9>IIn thIm to

!hoIt~

..tUng 191C'fied 1\ the bIgonning 01 tlla

""14 I"'~~dulch<-Section 17)

~~,....::I_ tI>e eprIng-.

21.13b .... taI tha _aligning !hoi m.kIng SUN _.n.n

IITOWS 11fTO~.

and IocItn con'IClIy ... _

15 AI !hoi ~ _!hoi Ij)eClIIed quantity MId typIoI new er1ghe 011 ( _ Chapl. I)

Wit ... pump

3 UnscrIw!hoI sump bolts. slacker1,ng II'IIm

."""Iy In I crtn·crlnt :lIqU&<>C4 to PI......,t dtstortlon, and lemove the sump IHI

Inldlrlllon) NOlI l1'li poIitions 01 !hoi wiring damp !WId '-'ring . . . ~ brac~ !hoi gMket ... I ' - or-.. ~ be .-.d. ~. !hoi pcJIiIIoow 01 !hoi dowets and _ thIm

o.c.ro

Not., n.. 011 sump, ,u.m.r and ~ '-'1IWve,*, be ~ with rn. ~ ... !/Ie f,.,.,. If I/Ie ~~, bHtr ",mo.-.d. /grIOtW /tie ,reps whJd> doI'rt IIPPIY.

Removal 1 R""ov. th. .xhaull 1.,.1"" (_ ChIpI.....). 2 DrMI!hoI.-.gI... oil 1_ CIIIpt. Either .......ova the 011 1...-.1 -"Of II .ltQuftd IHI ~ ... 11). 01' tr_ IhI wirI !hoi IJwIIch Mod dlSCOlllIICl It II the llinglt c:onro.ctor - 'JOAJ tnfI1 ' - to _ !hoi tn:nt eprocI<et OCIYW 10 acc.. 11 _ ~ 61.

n

"om

but'"

Silins 01

1 Puat>!hI.eIIet ....... plJngIw Into !hoi ....... body ....::I checlc that M ITIOYIS smoothly ....::I frilly till spring PI"'""". It not, .......ova Ille cIrcIIp. not'''iI that ~ '- undIr

J*mII'II'lIII'IrIId IocIdng

rnauntlng belts _

.ny

_OI'damageand~~_.new""" W--.&f)', Check l1li1 the 011 ptpas .... clew

.........

lItt.y . . , , - . .. tJnacraw _ 01 I t . - bolts _

..........

5 Pull thto PlItUU.. rIIl., valva out of tile

crlnke ••• {••• IIlul t •• tlonl . Dlaclld Ih. O-ring, .. I new 0fII ~ be.-l. Hrsquirsd, lIIISC ........ the botll Heuring tlla oil pjpas and PIA OUI !hoi pipet. DIIcIrd theO" ().rirIgs.

Inspection 1 RemowoI .. _ 01 QIIISkIIIrom the ...-np and aankcMe INbng ~ and ct..1 the ~ of the ~ _..w.nt. ~ the bam. ~ W~ (HlIlu$tnlI!on)

eprIng.-.c:l pb1get (HI _lustradona), CIaan .. tI>e~ ... 1OI¥wII....::I dIIdc thIm Ior.corlng. _ OI'~. H In)' it !<>
"'PIleI ttw ....... willi I

__ .....

In.tal/ation onlO till ,sIIIf valve....::l or-. thin puah ttw vIIve Into &OCkel In 1111 ~'Inkca.. lsee IIIUltration 22.51 F~ IIIW Q-rirIgs onlo !he 011 pipIII ....::I !II thIm Into theO" lIOCitets. "W1 a 1U,I.bll non'panna"",t ttlraao;l !ocklog compound to till PIP" boll IlveIds Ind bghI. . them to Ihe 1OI'QUII..,mng IIJ'I'CIfIe
Ita

10 "-1II1hI0I_ ~ maIung .... 1111 arrow po"''' to IhI honl of till angOnoI "W1 a Il.IitabIeo non·pIfTTWWII tIvIId Io:::dmg

.. 22.3 U....... w _ lUmp bolli, noting till pollltloM 0I1/1e braek.1I Ind clamp

22.5 Pull ilia ~ ........ rallII VI"" 0\11 ollis lOCk"

22.1 Remov. 11M bIIffttt pjall (a"owed) ~

~

Engine, clutch and transmission 2- 41 COI'J'If)OU'Id to IIw bOlts ..:I toghlan ttwn to IIw ~~Mt~.

11 W,~. lnS'-It U.. Dallle plale In_ .....-.p. U- apply. -.able non-~ Ioc:IurIg compound to _ bolt ____ ~

~

..:I~tt.nlo

~-..g

(_~22.0I n~.liIthe ....... ~ 1110 IIw CtInkcaIe. Lay • . - gasket

onto _.."., (11_ .......... In the........., or onlo the c:rankcaA (II _ ""0 ..... hu been ~ ..:I II poaationId upu;. down on "'" worIt 111<1_). Ma~a ...... lhe hoIe5 In the gasket IIIigrI oorNCt!)' with the bolt holM. 12 POII"on the lump onto th. crankC'A (. . . IIlu l t,.t1on). then !rIstall lhe bo11l. not torgatHnlllhe Ojl I.vel MnIOOr wiring cl.mp and f.lrIng .. de pa.... bracl<ets , ... lIIuII •• tion 22.3). and tight ... thenllVlflly ..:I • tttII at • IJmIIn a crtIa-cross pa\ta'n 10 "'"

~ \OrquI MttJng

13 ElIIMor ....1.11 _ oil level sen.or H ~ _ ChIpI. 9), or CO'Ir"IICt IIw won 81: !hi connector. 1nI;1M 1hI ~ _ M ~_~6).

14 FII_ ""Olne WIth the correct type and

..

quaI1tltyofoil_OIapt.I) 15 InIItalithe""-1,ya.n(_Chlrpt.-4) Start 1111 ""01". and ~k lor leaks around .".

23 Crankcase halves separalton and reassembly Kole: To~~m.~~11ta

......... lo.~"""'I111".."..

Separation

1 To _ _ till c.m chl,n and t..-...on. b*!e. c:oronect.-.g roda. CfaI'lkshBII. ~ InIrwnIHIon IhIftI. .....or ..... shaft and swt. cIvtch, IhI CtInkcaIe """* be spI~ 'nIO

---,

2 To enable thl <:rWIkcasa to be soparatod. thl "'Il,na mUll be -.moved fmm !tie Ira".. 1_ Section 5). BetOte !tie crankcases can be HPW8tod 1111 IoIIowIng components muIIt be ~ v.NICOO'IIO'"~I>Orl8).

b} CM>I cII.IIn f1IrIIIor.- _

-"

guides

1l!~Ior~tftr9J.

II)

0I.trern.r, -""'""" IWIIieI ""'"' _

011

~ts.cIiotl22).

f ,*,1tIJ/ _ oII,..,...sMIc/Ies p.,p,..- 9) , PIck-I.'PcoI~5). 5 ~ t h e _ ~ the right-hlncl cranllahaft and....,.... and ...nov. "" _ 1_ iIIu,tr.llon) Oisc.rd _ O·n""....

. - one must De UMd.

, Remova till TOOl ICIewa He"';"" _ t.e.tng retaonar ptat. to the rIght·haro::llicll of !he engl". and ...... ov. the pI.t. (," Hlu,ntlonl . 7 u~ the upper cranl
w_

~, ..,.;I !III radiItor brad<els (according to 1Il00II). Nole' A5 NCh boll II _ _ ,,.,,.11 In Its ,.." ... poll/ion, WIth Irs and

c.-. ~ or bo-acker...,.. ~ ....

CMdboMd,.".,.,.,. 01l1li ~"....... 11tIs willlInSU,. ~ bolts _ inslaI/IQ In /lle eotrWd'.toc.l>Orlon ~. 10 Carefully ~ft!lll _ cranIICNI half otI the ~ hoIIf• ...-.g • soft·faood I"Iaomrlw to

~

InIO 1111 ~ - ~ bolt 2S from 1111 ~ of IhI angIne),...-rtiI they . . ~­ lighl, !hen r,move them (," iUu,tr.tlon). Not. any wu/>Wa, leads and ....1Iing IlUiOn r.n.,;l .... ,th the bolla. Not., A5 MCh bolt " ~, .fIn II ... n. ..../hoe po$ifiOtI. WJfh Ib....,.,. Md orfPdl .......... ~ . ., .~~oItheaw>
Thr, wIII.....ute

~

bolls ....

Insf~1ed III

ft>I

_,.toc._on~.

e T..m 1111 angina upside down SO thai K .-.sts on !III ~ hMd studs. ,

U~!1111

.nd a

_

crankcase boII •

....,ty

UPPER CRANKCASE

2

lit!~

.! • t,ma In a ""'erA of th. ~ MqI.leI"QI shown an
then ramova tr..n (_ IlIustraUon 23.7) Mota the 'Nun.. IInl(l WIth some of !he

c} C)'IIfIdwhwdlSKl>Orl II). dJ ~bIocI< iSK"fJOn 1.).

• 0I.....,~22). I) QnchiSK"fJOn 11). 3 II _ crankCNW .... beong separated 10 ..-no.. 1111 crankll"llft • ...nov. _ pistonl 1_ SIc:tion 15). .. 111111 crenkc_ .,. baing ""periled . , part of . oomplet. engine ovemaul, 'ernovtI 1III1oIIowIrog oompooents, ~ 0/1 cooier (Sac:1>Orl 7). b} PlJIons (Sac1>Orl15). c) ~ mec/lIrIism (SectIon 20). d} 0/1 pump (SectIon 21J.

.., Sw,* 3). _~ _p.,p* p.,p,..-9j.

I)

LOWER CRANKCASE

-

bearing retainer plata ~wIII_. Ton.bltl.... "".."........

23.8 ••. and _

23.7 CrankeaA bolt slzaldentlllcatlon.nd tight_II uquencoo

2e42 Engine, clutch and transmission

23.10 c-tully Iitl the_hIol1 of1 the

23."11 R...."...thelargedowel

tap arouJ'ld tM IOint to initl.tty ...,.rat. the

and mtaliatiOn 01 the componentt tIouHd

"".. the mating aur1aeas 01 bolh crankcase _ 0 1 oil. Ie 1/ .--ed, lit the largo! Iocellno dowel into Il1o hole In the t.:I< 01 the enr"IIICMe. -.d lhe.....rl oow.t Into the moddll 01 ilia righthand 'ide. uaing • new C_rlng (I •• Illuatratlon, 23.11a, b _ 01 . n Apply I In"IIII amount 01 suItabiIo Matant (8UCI"I as YamahII Bond 1215) to tt-a out.. ""'tong surface 01_ aanIo:aM hall c.uHon: 00 nolapply en uceulw smounl of MManl .. /I will ooze out when rtt. case _-..blad .nd may obafnlcf 0/1 ~ Do "01 apply the MII/allt on w too .".,.. (within 2 to 3 mmJ to an, of the

withinthe~

bNr*Ig~Ot"~_

" " " - if ' - Y !_ iIIusIfationJ. Mottl, " !he ~ do not MF*I'te NSIty. ,.,...._

"" l'estene/1l!ww ~ ~ 00 not try and ~!e f"- ha/Va by leveling IlQ'IImI tile e,.,nke.se mallng surfecft .t IMy II,. ...uy se:t:nd WId wlJl/eak 011. TIP ItOUt>d !he joinllllC»3 wlllleaoh·/aoed"...,. 11 Remove the '-98 locating dowel ""'" the back 01 the eranltcue 81"1<1 the sm.Il dowel 81"1<1 M o-ring Irom the mH;ldle 01 the right. I\aN;:I SIde 01 the ca.. rthey could 1M In _ crenkcase hat/) (MIl IIlu$I1atlontl 12 ReI. to Sec:tJor. 24 to 32 lor

the......,....,

Reassembly 13 Remov • •11 trae .. 01 _I.nt "om lhe crar.kease mating ilUrfllCH. to( Ensure IhIIl an COMponefllS aJ'ld Itleir ~ ... In P*:e in the uw-_Iow.crankcese hatvee. 11 the _ ahans ' - not ' - ' ...-.d. ehed< the c:on
'*- to

temova"

h.,.... ... ...""s.

l ' Check IIgtlIn IhIIl all eomponenc. life in poaltlon. partieulat"ty Ihal lhe beIrIng lhelis a .. SI\II eorrectly located in Ihl lower crankcase h.~ . ca..fully fit Ihl lower <;fInkcase hall onto the upper er.-.kcaM half, making ...... the ~1orb-.comoctI\I inl0 thalr groov .. In lhe trartamInIon .... n ~ the cam c:/IMl ~ blade locates In the 1.......,.. and lhe dowels locate oorrectty ( _ Wlusltatlon 23.101. I t Check thllt tha lower crankea.. hal! is correctly seated. Note: The CtWW:.eN ".... ~ 6t togetIw wtthouI being ro..:.t If /he ~ _fIOrconaoc;l1Y_ted,_the 10_ C/"I/"IlIc.au half and InllQllptla /he probiam. Do IIOt al18mpl to (J4JI them together ulil>g the crankca.. boI~ as u.. eung will crack and be rulfl«1. Mal<e Sura the outpul ....tt and cllJ\ch pUShrod oil ...... are correctly seated 1_ lluItntion).

... 23..11 Make __ the 011 _It _ MIIted

23.11b ••. the ...... I_Iam>wadl.

!III.....adI·

_helf

corra<:Uy

23.20 The two 1 mm bo/1I on each to"Id (arrowed) hII ... steel "' . ........

23.lIc ••• • nd/taO-ring

20 Clean the Ihrudl 01 the 9 mm low.. eranl,,:... bolls (N.,.. I 10 10) 81"1<1 .ppIy ~ disuIphide 011 (a 50150 mixI... 01 ffiOjybdenum dl,ulphlda graase and new engine oil) to INoir IIYNdI. InSllf"lthem. with the - . . . . on bcIIbo t 10 10 1_ .....trItionI. In !hair orig,naI Iocat""" 1_ 1I....... tion 23.7). CIewo the _ "'the 8 and , mm lower crankcne boI1, and apply new englnll 01110 lhelr Ihreads. Insert tMam (willi the radiator tncl<ets where fttted) In their ongInai iocatioruo ( _ lIIustrallon 23.7). s.c.n .. bo/II r.,gw-bght at tnt. tIwo tighten them . - . , and IIinII at • lime in the (:(IITICI. ......wIcII sequance 10 lhe lorq .... "U'!"IgS ~ at the begInrWIg 01 the ctoapt•. 21 Tum the engine over. Clean the IMread. 01 tr.. upper cranke... bolls and apply n_ IIIIglne 011 to their IhrAda. Insert them. nol ~ the oopper WIIIhoIr IIII"itI"I bolt 24 ! Inusltatlon) , I8IIh INd Wllh boI1 30 1_

Engine, clutch and transmission 2 - 43 tt>e lorque HIlings specified at the beginnlog of !hI Chaptor.

22 With al l crankcase Inlanan lightall8d , check that the crankshaft and transmission

shaft. rotate smoothly and _Iy. Check. th8t

23.21b ••• and

ttl'" one ...,......

."

the ... rth

IlIuSlnotlon). and IWlY leads and wring guIdM, In th"r original k><;atlons { ••• Hluslnltlon 23.7). Secure all bolts ronger·tlght 81 flrat. then light.., !hem IW«\l)' and I ~t1je at • time in the correct numarical sequenc. to

the transm ission shafts rotat e freely and Inde~danl l y In nautral. than rotate the :tMetor dn.m by hand and aeIect each II"'" in tum whilst rotating the inpul _n. Ct>OCl< that all g&l1ftl can be ~ectad and th8t tt>e shafls rotale Ifeely In avlfY gear. If there ar. any signs of undue stiffness. tig~1 or rougI1 spoIs. or 01 any othar problem. t~e l a u~ must be recfj/ied before proceeding Iurttw". 23 Apply a su itabie "",,·permanent I hread lOCking compound 10 tha threads of the bearing retainer plate Ton< screws, then rrt the ptate and light"" the screWS to the specified t0fQU8 setting 1_ 11Iustnmon 23.61. 24 Fil tha right-hand crankshaft end-covor u$ing a ' - C}-rIng and lighten the ~ 10 th' spac ~ied torq.... setting I_ Miultnlllon 23.5). 25 Insta/laii o\IIef r!llT'lO'o'ed assemblies In the . - of the seQUenCeS given in Steps 2. 3, and 4 accoroing 10 your procedure,

24 CrankcaM halYes inspectiOn and S8fVicing 1 Aftor the crankcasas ha\rtl baorl separ8Ied, ramove Ih' crankshaft and bearings , cam chain ten.loner blade, transmission shafts. selector drum and lorh, Hy-Vo chain gUKM

_ . stanOI' dutch and Il/tomator drive shaft and beartngs, and aroy other components or assemfljies 001 already removed, referring to the ..,Ievant Sactlons 01 thla and other ChapwB{_ Steps 2, J. and 4 in Sect""" 23). 2 Unscrew the bolt securing the 011 nozzle plate and ..,move II Md lIS gasket, then witlldraw tha nozzla, noting how it fitslsaa llluatretlons). UnllCfew the bojls securing tt>e 011 spray pip<.> and witlldraw it from the crankcase lsea m"stration a). Discard tha O-rtngs as ' - ~ should be used. Unscrew Itle bo~a sacurlng tha 011 bal1le plates and remOve them. nOling which Iits whe and Its mounting rubber (_ iUustratlon) , J The crankcases should be ~ ... nad IhOfO
w. .. All traces of ok! gasket sealant should be removed lrom Ihe mat ing ....rlacas. Minor damage 10 Ihe surlaca. can be clean&d up with a ~ne sharpening .'one ... grindslOM. Cauf!on: Ba very ca,..ful no t fO nlc ~ or I1OUl/t' fh. enmke.sa m at/nfls.url_ or oN leaks will ,..sult. Checlr Ix>th c rankcase halves ""I)' cereful/y for cracks end olher

-....

5 Small cracks ... holes in aluminium castings may be repaired w~h an apoKy resin edl'lasl\oe as a lemporary measure. Permanenl repairs can on ly be affected by argon-arc walding , end only a specia llsl In thi. process Is in a

2

24.2d Unser_

tIM bolt (. ITOWed) _

tIM circlip and withdraw the oil ratum pipe

2-44 Engine, clutch and transmission atakad. flit '- a aplit·hnk type and It

COI'I1M

IPIit. then tt.'a ia no need to disassembIa the engine and ....-rlOW Iha cnnbhaft to r~ the chain, IIIougI> the cylinder head mUSI be

removed (woth the camahafts In situ) ( _ Section II, taklng note of sit the Infermahon In Note 2) to avoid Ih. possibility of a piston COntacting a va"'l whfln thll crank~aft Ia baing turned wiIhcut the ~ attached to ttw c.nshafts. lithe chain '- btong to .......ave the cyIind« 1\Md, and b not being replaced willi I ' - 0f>I. you will need 10 obtain I . - aptit.fnk ""'" yo.x dMMr ~ you ctnnOI ..-..... the old one. Notl: Due to the Iricky nawe of splir!Jng .,,;J }oIrwtg chaIm. .,,;J !he I>IHId for speeiIJI tooI:t, and !he fttct 11181 IIflItta the job Is dOllO ptrJptrly the cons1Iquence. could ba dire, II may M balllr 10 /lave I". CIlain split .,,;J /Oitt«J by a YIrtI'WIoi dMJtJr. If a new chain comN spill. eonsJder hlorlnQ II joined by !he . . . . ....".., you 00y II,. and a.n iii it convenl>Onall)' dirKI/y IIOUfId llIe cntWshIlff and bcJIId /tie engtr» up _ IhougII !he chan __ ....... Mhough!his ......... more worl\. tlla reptreUuion! of a NdIy .taked CIlain coming wilen the .-.g.;-. II fIJr!fWng should not IN iNldNHIJma'M. Warning: U•• ONLY Ih. cOffeel , .e",lc. 1001. /0 d/lilu.,.,ble Ihl split_link _ If you do no/ hUI ec.,.", 10 .uch 1001. 01" do nol h.wI Ih. .klll 10 operete ,IIem COf'rW<:IIy, h ..... the chal" _wad by • deeler HtVIce depMment 01" I:IM:. """-Ihop. II you decide to apht Ihe cha,n and do the worI< yourHII, ......,... Iha valva cov..,. (... Section 8). Ihe elm chaJn tensloner (... Section 9) and the cylinder head (... Section 11 ). Belotl aplltting the cam chain, mal<e a relerance mark batwaen .. link on the chain and a tooth on Ihe aproc;kat on Mch Ii<:» of the sptR h 80 thllt It e... be Ina'*
"*

24.8b Me .......... 1M tab on 1M fM~

il4.8Io AlIgn It-. pin on It-. nozzle with It-. Iiot in It-. crankc. . . "'"OWed)

(1n'OWed) IocIt.. be~ It-. lugl on 1M

IX*1lon to advtse on the ~ Of practical aspeo;t 01 such a repair. II Iny damaga ia lound that can't be rePIII.-.d, rltOIW the cr..,kcoIM ha/Yes as I HI. e Oamagad threads can M -.cOl'OC)mlo;alty reclaOmed by using I diamond Metlon wira 11IMI1. 01 the Heli-CoII type, which b.asIty lined all. ~ and . .~ It-..tfected

making lura tna tab on the plate local.. between the luga on the crankeue, and tighten the bolt to the specified lorqua (I. . IRustration). II Install the cranksh.afl and beIImg., ...... cI'uIin and t....... blade. tran:smission IhIIftt, selector dnm and 1Qrb, Hy-Vo cheIn. 11a'!. ct.JICh and a/t.-nator dnve shaft and ~ befI:q ~ the cnnkcaM II"--

......

7 Shaated Ituda ot ~ can ulualty M .......:wed with Kt1IW extnoctCQ. which consist

01 a tlpared. ~ft thraad .craw 01 vary hard ItMi. n- are Inserted "'to a prNrljlad ho~ .., the atud, and uaualty IUCCIed In djslodging the moat l1ubbom stud Of Kt1IW

crani<ease

25 Cam chain and tensionef blade - removal, inspection and instaHatloo Removal

e iMtall the clutch 001 r.tum pipe with It. rubber mourning and IICIJre R with tile cirdip ( _ lIIus t .. tlon 24.2g) . Install tha 011 blfl~ ptates. thltO appty a suitabia nOfl-PItO"T'anent thrtad Ioc;klng compound to the thraads of the bolll and tighten tham to the totque ... flUIO specified at tha beginning 01 the

_tal

Chap!.- 1_ iIIustnItion M.2fI. tn. oi IflI'8Y pipe ...-..g MW o.mg. and !Igh*' tn.

boh to the specifoad torqua Mfling ( _ Illuatr.tlona 24..2. and d). Align the pm on tn. heed 01 tn. oil nom. with the -'
Cam ehaln 1 ThI origl,.., ~t cam chain hili a staked-type s.pIit-llnk which CIIn be ~bIed using e/1!w a yamaha ........ tw, or one of ~ commert:ially-availabla drive chain cutt;nwataking tooIt., so)lOU don1

hava to remolla tha crankshaft. Such chains

can be rec:ognlaed by !he spO't·h IIde ptate'. !dentlflcatlon marks (and usually Its diN....,t coIourI... wel .. by tn. staked endl at Iha link'. two pi<-. which 100II_11 !hay hew *-'

other.,...

deeIlI'I~r.st-fol~ovet

_ with .. the t - iIIl.o&tmIortI. lIa new cNin '-~, or it you .... _VI"!I the cytlnder heed with the camshafts in .. tu (see Sedlon 11), o;f>eck Wl1h yo.x dMMr III to whether the cI\aIn eornes a s a spIlI·llnk type. or whole. and If II Is • split-link type ch.'n, whether 11 Is .... pptled with tile link sptit or

"'*'

A

...-.

Tensloner blade .. RemoYe lila cnnkIhafI (_ Section 28) 5 UnICf1IW lhe bolts MCUring the tIIfWonar bIada baa to lila awokcaM rod """""" Iha bIada ,_

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2- 46 Engine, clutch and transmission

27 ... Unscrew the routs (wnIwedI ..-d ....,ov. the c:onnecti"'ll rods

....,.t.

4 Unscrew the CONIeCting rod cep nl,lll and the c.p I,om the cr .... kpln ,_ ~. Do noI....-ethe tIOIUI from the ~ ItnrnediaIwt InWIII 11-. ~ bNMg ~ CoI~, bMrIng cep. and nuts on .-ch plslon/connectlng rod assembly 10 U\St they ... e aU kept together as I matched set 10

....... oorrect 1nttaIlII1i<>n. Inspection ~ the <;:OrnICtlng rods lor cncks and othIr otMouI damage. S Apply clnn .nglne oil to the pIston pin. "'-t It ~to Its connect"'o rod IIITIIIII....-.:! and check for any ~ bMw""" the two ( _ ....tralionj. "/rMpI8y II _ , . . - . . e the pin •• t_1 diamet. (_ IIkmration I 5.13bJ. Compare the rwuI! 10 Iha IIPM'fficAIionII althe ~ of Itle G/laptillr. Replece the ~n wllh • ntlW one 1111 Is worn I:xtyond Its specIIttd limits. H the pin dlemeter Ia wlthlll speell"=ations, ~ li"ioi connecting rod with • new .".,.. RepMt the _Iorlltheroda. 7 RII... 10 s.eloon 26 and e •• mllle the connecting rod bearing shell •. If they are KOr..::!, badly Kull..::! 0, apPM' to have Mil..::!. new ..............1 be Imlded. oIJwa)'!l . . - - the sheila In the conrMICbrIg rods IS I HI If they ar. badly damaged, Q>eck the ~ crankpin. EWiInot 01 elCtreme hell. such as dlKoioratiQn, IneIiCII" Ihat lubrlc alion fal lur. hu oceurr..::!. Ba .u,e 10 lhoroughly check the oil pump arw;I pr&llSUl'1l rwoguIalor IS WIll • all oil haIlS and peuages bIIofI ~ the engno. , Haw the rods checkId lor twist and bind

5

27.11 Make .... the tab !Alloc.te. In the notch (B)

27.e $lip the piston pin Into the rocr. ........ -_ _ rock It beet< and forth 10 check lor Ioo.-sa wyou on in douDt about their .\relgn_.

b'J" y.....n. _

011 clearance check • ~ new bNTIg ....... &AI bWIg fined or lhe original onea Ira being ra-uHd. the comectillg rod (big-eod) bearing 011 clearance ahould be check..:! prior 10 ..........,bIy. 0tItaIII . - boIbI and nuts lor the contlICI.o"og rods and .-c.d the old ...-. 10 RIrncwe the ~ ....... !rom ItM rods end ceps, klHlJllng lhem in order 11_ IIluWltlon). Clean ItM backs of the ~I. and lhe bearing Iocaliollf; In bOlh the conoecllllg rod lind cap. and the crWIkpin joumII. II p,... the bMIIng aheIls into thalr ~ -..ing ItIII the tab on -=tt IhII &nOIOIS the notch In ItM connectIn!i rodIap (1M 11I0.tr'3tioll). Make IOI'e the bearIngI are lilt..::! In the correct Iocallons and taka care not to touch any shell'. beartng aurtace with

_......

12 Cut e lellgth of the apptOpNle -'le PIaabgauga Crt shcIo.*;f be IIigtIdy ~ !han ItM width of the crankpOll). llrand of PlasligllUO" onlha erankpin)oumal. 13 Apply molybOlllom dlsu lphlde gr_ to the boll "'-'ks and tI"oNedI and 10 ItM _ _

1'1_.

of the outs. tt.. fit Iha bo/ls Into the cap. F'tt !hoi connectIng rod and cap onto lhe CI'WIkshaII 1_ iIIuItralion Xl.25j. Make ..... the c.j) " fitted lhe QOn1ICt w,,", ... DUIId to ItM previously made m~ aUgn. and thet the rod II facIng the I1ghI way 1_ Step 3). F'tt ItM null and tightflll them llnoer-tlght. making ...... the C"""",,,lng rod don not rotlla on ItM a-ankIhalt.

27.21 Bill-and journal 111:....... bara !Al, main Joumill-izi nurnbefa (0)

Xl.l0 To ........... I

bit-..-d bNlintlhlll,

push It aidewly8 and litt it out 14 T\gorIlen the cap nuts to the initIaIlorq ... Mltlng lIoPICifoacl at lhe beginning of Iha Chapt.. m.kIog .... the COI'IIlICtlng rod ".,.. not mlale on the c,ank$lulft 1_ HlustrllJolI 27.26). Now 19htlll each nlllill lurn and In one COI11,nllOU1 movement to the final tl)r(t .... s-etling .peelfled. If bghleolng It paused bet-. ItM InIbIII and flnII aetbrIgt, ~ Iha nut to below Iha IrWUaI MIting and ~Iha~.

15 Slack.n the cep nUll and remove the care oot 10 rolale lhe rod or crankWft 16 Compara lhe wldlh 01 the c"""'-d PlastlgaUO" on IhI crankplII 10 IhI IClIa pmted "" the PIastigauge ~ 10 obI.aIn the oomectWIg rod ~ oil cIewanoIlIM Inua lration 26.201. Comparelhe ...dlng 10 the lpeclficliions at the beginning 01 the COMICIIng rod. apaIII taking g<eII

-,.

17 On compIelloll caretully tcrape IWay II tr.c:. . of the Plasliglluga mIIlarial f,om the aankpIn and bIImg IIheIt .....-.g e ftngImaII or other ObjEt which iI unIlkwt 10 100I'I the

-.

16 If the clearance II within Iha ranoe lilt..::! ~ thit Chapta'. Spec/fIea1lons and ItM bearlnglI ... in perIac1 ca-odffion.1h&y <;an be....-d." lhe CIeat'IIlCfI it beyond the s.vIc&> Imll. rapIaQt ItM t.n.g ..... with MW ..... (.aa 5t"" 21 and 22). Check the oil ~ GrIC. Iogaln (Ihe new 'helll mIIY be th"=k enough to bring beiO'lng clearance within ItM specitI&d atltM _ range). _ .A/Way8 ......... as of the IhIII

."u

It It Iha cIeatance II greater lhan the servlcl lornll lisl..::! In Ihi' Chapl.... Speclficenona. ItM bIg •...-.:! bearing journal it WQITl and the cranl
Bearing .nell aeleetion 21 R " P I - ' bNrIn; shell, lor the bog..-d beanngs era SUppli..::! on • select..::! I~ basi •. Code numbert stamped on various compooenll are used 10 Identify the correcl ~ beariroOI. The cnnkshaft joumaI ala numblra ... Itamp&d on the oII\aIde of the ~ web onlha Ieft-har>d end 1_ Hluatrallon) The righi-hand block of , ...... nurnblra ... lor the bit-.n
Engine, clutch and transmission 2-47

27.22

n.. colour c~ II ",.11<-.;1 on u.. 8Ide 01 Nch bearing

n..

IT\IWl ~ iOImIII). first nt.mber of thoo Itu II tor !hit lift-hind (No. t cyIndIw) joumIoI. Ind 10 OIL EIldlI;OIWI8Ctlng rod size nt.mber is mar1ted In In~ on tIM fI.1I !ac
c:onnotClJng

tOd

.nd

cap

,_

~21.31

22 "fWlgeol~st.llllIIIIVIIiIabIe. To select tIM COlT..:! ~ lor • partll::ular ~ rod. 8I.ItIIr.ct \he bIg...-od ~ joumaI numblor (slarnped on tile cranI< web) from tIM ~ rod nurnbtr (rnarI<ed 00 Ih. rod). Compar. 11M bearing nu",bef calculated Wltll the t.bl, beklw 10 find Ih. colour cOding ot the rep4ac..-nent bN~ng required. Th. coklur code is mali<ed on the Side of ..,.;h ~ , _ IHu.tration).

,......

......"""'"

ZJ CiMn the t.cQ 01 the bMrIng _ _ ..., the Iocetlo:Jrw In _ 1M connoctlng ~

crriPn (11M 1I....l ratIonI.

Make . . . IhII CIIl

is litted the corrKt w.y IIfOtIrI
__

~1#nId to ct.. oI'Igh"ll' IocationI UIIng the ........ madeon~. 28 Tlght ... the cap nuts to IhII initial t~ letting ~,t*' .1 Ih. beginning 01 tIM ChItpt ... ,_ IRuslrallon). Now tighten each nut In tum and In one contU'lUOUS rnovemerrt to lhe Iinal lorqui setting speclIHKI. II tlghl ... )ng" p' '',1ud betw",," Ihfllnltlal.nd final . ."Ingl. ,Iack.n lhe nu' to ~ow lhe InIIIII Htt~ aod ..-peat the procedure. 27 ChecII tl\&l the ro
- ..-

0-

Inatallatlon

........... the oonnecting rod and <,..:> on 1M

""'~24 Prw. lhe bHrIng IheIII inlO thetr Ioc:rot~, ma/
with cIeer1l111Q101 011. 25 ""*t moIytKIInum disulphdtI 11'_ 10 thebOlt..-.-a..., _ _ ",,,,,,_ of tIM "1111. t"- 1,1 tIM bolls Into "'" c.p.

frwIy 00 the~. " u.n ... ...,.,;g". 01 ~ or liOhIr*&. "'"""'" "'" rodo and ...-cr-k the bearing c'-..-.:e. SotnetimM tIppO'>g the boUom 01 the oonnecting rod cap wII ..... . - . but ~ in dcut>t. ,...;:hedc 28 In8taII the CI'II'"Qhaft (1M SecIJon 28).

28 Cranksh8ft and main

bearings - removal, Inspection and installation

~

'"

~

Note: To~ .... Ih. crank.sh9f111>e Ing/ne must be removed /rom lhe lr.mfJ .nd 1118 CIa"IkcaH /laMe sep&rIOleO".

Remo"al 1

~.

11M engine Irom the ".me 1_

Sectioll 5) rod Ml*'ate the ~ heIYM (Me SecIIon 23). Rem;we the 8II_or drM ""'" rod Nfl... dIIIdIl_ SecIIon 32). 2 lift the CfIrIk8hIft out 01 the uw« monk· c:.M hall, -.g ani no! to dislodge the " - ' bNrIng . " . . then ...-nove the cam c"'" ... and I-ti-Vo cn.t hom ~ 3 II~. _ _ the ~ IIhIII from 1M cnnkaM ""'- by pusIWIg 1hIIr centI'II 10 Ihe eide. then lifting lhem OUI , _

,_IIuItrItion).

Illu.l.atlon) K"'II lhe """'.. In order. On

VU1000A modell, not. !hat rII ~!of the centrI jot.omaI tJ3) have no groove. 4 II ,equl,ed ... pa,at. lhe connecting rods from the Cl"lnkoh./I 1_ Section 21). NoIe: If no~"lOb&cani&dO<Jton""'~" 01 connect'/IQ rod assemblies. '''''' Is no

rOMd 10 aepwabt IIW7l

InapeCtJOn , CIIItn the ~ wI1h IO/'Yent, ...o-.g • nlll-clHnl/"O(l btuIh to Knob out the 011 p&MIgeI. II '*>ow the cnonk ~ with 00f1IPI-' •. aod -.0 blow 1I"Irough the 01 p&MIgeI. CIIeck 1M primary dIM gM". cam cNIn ~ rod I-ti-Vo c:Nin spn>cI<.t lor _ or d&m&Il' t_ htuslnollon). If any 01 \tie t. .th .ra ,x(:IIul .. &ly worn. chipped or broken. Ihti CI1IOka/'IaIt must tle repIeced w11h • ' - one. rt _ or damage "'found, chick the driven gearoo lhe clutch housing. I Rtl... to S1ctioll 26 and ~ the ~ bNrlng allell •. " they ..... scored. tndly KUlled Of appear to havtO beefI seized. ' bMrIngI must be installed. Always _ _ the bNrI"1I1 . . . . .t. II they "'0 bOdly

....w-.

m,,"

dam8Qed. check the corresponding CfItIk-

2

2- 48 Engine, clutch and transmission I to".,. In the comoct numarIeaI ~ 10 tile torque sett.IgII IPIQfIed 1\ tile begonnIng 01 the ChIIpt •. 17 Unsc ....... lhe upper crankcase bolls fffl1f'it and I Uttla I I I Ilme In I ffIY8r$II of the numerical sequence shown (_ lIIu . trllion 23.7) and .. marked on Ih' crlnkcase (' he number of INCh boll Is ClSt Into the cra->kcMI), I.O'II~ tilly _ fIngar.1lghI, remove lham. and pIaca tham back In

"*' 28.13 Ley I I trip 01 ""slipou9l on HCh ~ ... to Ih4I c.-.nklhal'l ~

joumIoI

_II journals. E-mence 01 .. ~ 1ItM. auch

., d lS«lloraHon. Indica!" th. t lubrl~llIon 1. llu r. hn oc~urred. a. IUr. to lhoroU(lhly ChICk I'" oil pump .,., ~. regull.tor _ well I. III oil holes Ind PIIHQM belorl .--nbIFog It. . . . . . 7 GrvI the cnnkshatI ~ I dole IIIIuII _1nItion.~~~

......

dImI.gId ~ have bIIn dlIcoYIrMl. It the ..x>tId 01 pjtlMl in .-.y ~ • .... w crlnkshlll will bI rlqulrld. NOli thai un
""""* ..

Oil ctearance check , WhItI\er ' - bIIrIng .,..... .... btoIng ftttMl or the orIgln-a1 onN ara bIing ,.-uud. tile main bIIrIng oil c\6amncI ~ bI checked betorl Ih' engine la , aassembled. Main beating 011 eI .....anc. Is m... ured with. ~ known as Plastlgalge. 10 II no! Ilrud\l doni. rImO .... Ille beerlng shells fn)m the ~ halves _ Step 3). a.., the bIcIta 01 the ....... InC! the ~ houIingI in boIh Ct~ hIIYM. and !hi main ~ joI.mM: on the~.

11 PrM, lhe beartng shell. InlO lheir cutoutl ...... unng HIlt the tab on •• ch shell ~agft In Ih. notch In the Ctlnkcase (_ Illull.atlon 28.28). Maka IUri Ih. bea rings Irl fitted In lhe correct 1000UOni Ind t.k. care no! 10 louch "'" bIIrIng aurfsocl

....u..-.

,...."..

IhI CInbIerd \empIIIe, " UNd. 18 Tum tha ~Inl upaIdt down 10 ,kit It _ on IhI cyIirdIr '"-:I atuct.. making .... the cnnkshatI doe. not lOlita. II Unscnrw thei0Y09 crankcase bolts IYerlIy

.Ide.

hi nd u,lng a new a-ring (III Illu,,",Oonl 23." •• b and c). carefully InalaU the klw. aankCIH nail on 10 \he upper nail. making ...... IhI dowel Iocal_ COO'"ttOCtIy (_ IlIua"llion 23. 10) Chick that lhe' low..crric.l hall. ~ _lid. Nota: Do notflVtllWllIM~_Iftt.~. not~w.ted.

15 Clean the t/'I(~ 01 the 9 mm low.crankcase boll, (~. 1 10 10) and apply rnoI)txIIrun diIuIpI'IidI 01 (a 50150 mIxt,.. 01 motybdanum dl.ulphlda grease and new ang;n. oil) to !her.- threedL m-t them. with the washerl Of' boItI 7 10 10 1_ illu . .... llon 23.20) . In ttlllr origlllll locations (_.......-.tlon 23..7) . 0-. tt. ~01 tile 8 and 8 mm ~ c.1O'IkcIse bolls InC! IflI)Iy

' - engIna 01 10 their 1tIr_. I..., them (\oIIh the rachtor ~ where Iit1IdI in tI\eIr original locations 1_ IliuIb"MIon 23..7). 5K:tn .. \;W)l\l1Inger-tight 1\ rnt. tl*l1igMerI tt'Iern ~ and I little at I timaln the COfTI(;I numerical sequence to tile lorque HlIlnge speciIIed at the begInr1ing of It. Chapt.

Ie Tum tha II'lIJln. 0 ....... making lUll lhe cr-*Wft doe. not rotate. Clean tile tI'IreadI of tile upper crankclll bolts II'ld IIpI)Iy ' eng ..... oil to their Ihreads. Insert lham. noI forgettong !he copper _ with boll 2~ 1_ m....... tIon 23.21.). earth lead with bolt 30 1_ IMustration H.21 bJ. and "'" IaoadlI _ wIr1ng ~. In tnelr orIginII Iocalions t_ iIIutotmion 23..7). SIcufI .. bolts linger-tight al !hI. therlllghlen !hem I\IeO"IIV rod I littII I t

shill·,

"""* I-"'trrion 2$.21 13 CUt~ _ _ 1Ingtha 01 the spproprIallllze

PiullgauQl (they should boo slightly ahort.. Ihln lhe width of Ille ~renksh.ft Ioumals). PIaOI' I strand of Plast;gauge on each journsI. maklng ...... It will be e1Mr of the 011 hoitIII In lhe . hl ll, wh .... lhe low.r c,"' k ~aSl I, Inltilled t_ Illustration) . Makl IUri Ille

28.24 Mlin

rotal.:!.

,. If rImOv..:l. ~I the large 1oca0ng dowel into Its l'ioii in IfII bIcI< 01 the ~. InC! the _ dowIIlnto the middle 0I1hI right-

"*'

,hem.

oft theiower cranI
scaIII prinl..:l on the Plullgluge envelope to obtaIn the main ~rir.g 011 cl,arance (s.a IIlultratlon) . CemPfor. the rladlng to Ihl 'f)lCffical000I .1 the blgil'll'lll'l\l 0111>1 Chapt. 21 On completion carelutty scrape a....-y l1li IrKfl; of Ille Plastogauge mlt ...1 from the cnanbhalt journal and bearing shells: UII • fingernail or othIt oo,act whocI'I itlrikel)l 10 ~...".

22 If the 01 doNrancI f. Inlo the spacdiad no beating shell ,eplacement Ia requhd (provided thIy .... In good oonditionj.

'1fI9I.

Illhe clearance II beyond the HrVlca Ilmli. on the CMI rod tile markl on Ille cranlc.shlft and IIIIcI .... w blaring IhIIls 1_ SlIP' 24 and 25). Install the ...... ...... rod cI»ck l1'li 01 oto.anc. <>nC:I1jpIn {It'll ' - IhIIls may bring bearing doNrancI within the "I*'fIled ....) ~ 'eMW . . ref. 10 the fTIIri
01 the II'Iek II It. ..... un.. 23 II the clearance ~ Iltll g'Nt ... thin !ha lerVlc:e Ilmil l,.ted In thla Chapl... •• SpeciIIcatooos 1_ with repIIc:ement sheiIs).

I"" Cta nkihaft toomll I, wom and tha crankshall should be rtnewId. Maln bearing shell selection :z.. Rapiac8fTllOl ~ ....... lor the maon beerings . . suppIiIcI on • MIactNe iii beIia. Code nu~ IllrtI!'Id on VIlnOl,ll components . . t.OMd 10 1cien!Jfy \he comet .-.pIaoerrMot t..1ngI. ThI cranksI'Iatt ~ "~I numbenl _ lIarnpad on the outside 01 IhI cranlc.stoaft web on 1hlIaIt-hlrd end tIllustration 27.21). The ten·hand block of fivI runbers .... for I"" main bIerIng journal. (\n. right·1Iaod block oT four numben! are for the

12 the IhIb _ crankahIIt . . dNn InC! cloy. lIy the cra-.kshaft in ~ In IfII

~tt. not

and I I;We II I lIme In I r.v ..."" of Ihe num ... lcal uqu .... ~e ,I>own (S.I lIIu l tration 23.7) Ind u mlrked on In. crankcasa (Ihe number oilleh bolt 1& cut Into the tra'JkcMlJ. I.0'Il01 thIy . . finger.tIght. rIf'I'I(WI Ind plica them back In It. <:a'dI:>oerd template. If UNd. ~ lilt

bIIrIr1fiI housing ~ D No. 2 Joutr-I ~

A No. 5 /OtIIY* fJ5J

B

No.~;wntlltJ4)

c

No.

3Joutr-I Y3)

E

No.IJoutr-Iy,}

big-end bearrog journaIIj. Thlilrat I"IlmbIr 01 It. fivlia for 1hl1aIt-hend (No. I) journII. and 110 on. ThI maon belring """'*'0 nurn\:>enI . . . . . . . . intothe'*'" 01 the """'"~ hili' f_ ..... tntIon) ThI ... number 01 the

Engine, clutch and transmission 2- 49 n...illlorthe rIght-hMd (No. S)jaurT"-', and 10 on. HOI. 1""1 W u..r. Is only on. num"~ Into the~.I1 ..... thai .. thejoo.o'nllll . . the ....... ro.rrt>er :t5 A I'WIgtI 01 belong ..... ill 1.aiIIIJIe;. To HIect lIMo oomcl bNring for I pwtocullr journal.... b l.1et lIMo rna," _ " I I joumll ro.rrt>er ~ on the ~ wmj from the m_n bNrtng haulIng nom"" (,limped on the cnnkcaH). eomp.e the bMrYIg.......m.. CIJcuiated Wllh Iha tatHe tJeIow to find tile

...

colou. coding of Iha '.placement bearing ~"

nF750R end SP models: N ....... bef

,,,

28.21 M.k ...... _ tab. on the """,I. local. In tile notches In the cutouts

......

Colour

27 tf .amo...-d. fit \he connect'"!l rods onlO the CtriIheft _ SectIon 27). 28 Pr.a the bearing aIleIls Into thei. Iocatoonl M......... tIM! tab on each ahell IfIOlIOM In lhe nolch In lhe casing 1_

V..."

"'-

YlFtDOOR ...odIk Nota, n. beerlng _ _ for joumIII 3 _

--

~bylhl.leckol_~ N.......,....~ ·

JI , J2. .14. J5

....,...

PinklBW:!<

PinkIBrown

PinWGr-,

~.

J3

IlulCnIion) MIke __ the ~ . . lined In the COffICt IocIhO. . and take c.rtI f'IOI 10 louch any 1IhII" bIIIring ... rlaca with your ringen. Flemember 1""1 on YZF 1ODOR moOIII. the ........ lor lhe centre journal (J3) heW no centre!jlJ'OOV'8. end era~-ooded 0'" ......11y ( _ litHe above). Lubrlcala NCh _ with clean """"" oil.

-- .... VIoIetl8lack IIIoIetlBrown

""""'- ""'"""'""' InstaJ/stlon

2111 II not elreedy done •• emove the bearing ~

e

h

t

shells from tht ~ tIa/'4 a-.lhebel;l
29 Slip lhe el m chain a nd Hy-Vo chain ~kllU on \he c.ankshaft ( _ lIIu" . a tlon) . Lower Iha crankshaft Inlo poI/tIon In lhe lIpp8I" ~. making ...... In bNringa remain In placa (III around the

.....,,.,, '""""'"

30 ReeMamble tile

cranl<.cil~

lIGtvH (XC

NO"' To _

Removal 1 RafI (III Mhntrltlon) II ~uir.:t. I'1ImOY'II tha Oil .... from the left-hand end 01 the DUtpUt ~ 3 UII 1111 Input ....11 and DUtpUt shaft out 01 IIMI aankCMI. not>ng 1' - raIe\lYI pos/Iionfi In the crankca.. and how they lit 1000Ihar (_ m...lratlon) . ~ they ..... stucI<. "'" a 1Oftlaced hammer and QIIflIIy tap on the encII 01 the ehafIa to """ them. 4 RarI'IIwe the two t-Ing half-ring rala1nars

!rom lhe

crankcasa.

noting how !hay ftl ( _

Ilklltratlon) ." they era,..,. in their slota in Iha c.ankc.... 'amove them lrom tha bearings ~

Ii

on Iha DUtpUt shatto the -..fts can be ~ or damage (:l1li

K~,

and lnapactad lor _

-"".

In.t.".tlon

29 Transmiuion shaftsremoval and instaItatioo

""""" musr be

28.28 Loop lhe cam chain and Hy_Vo chlln around ttII 8P'O"klts •• Ilhown

the

~ 5I!a~

..-no"'"

Iha

fmm the flame and

the crJIfI/
II FIt the t..W>g"",-mg f1IIaIn.-s Into trwaIotl In tile upper c.anl<cua hili ( _ .... tration 2II.a) . 7 Low.- tile output shaft Into position In the I.IPI* QankCIII. making sure lhe ball bewing

Ioclling pin 1",," back . nd locates In III

r-~~..,

211.2

~

the clutch puthrod oiIlNllAJ and II ~ the 0tJtp.rt -"aft oil _ I (8)

IAJ and 0tJtp.rt .....1t (8) out of the ."ank.,...

29.3 U1't tile input ahatt

2

2. 50 Engine, clutch and transmission ~, and the groovw In the bNnngs engage comctly with IhI hllf·nng reta.Mrl l_~ )

8 Low.. thllnpo,ot ahlft InlO P
211.4 " - " the IuI"-rtnu

_

....

hl

ln_.,...,keHe

~ from or _

-.......... t.....owed)

pinl_._. . . _..

211.7 M.... ...... _

~

bioi beartnll locIolIng lnlt.

..-.. IAI, and _lIroo_ In the t.e.r1ngl ..,gege eonwctty with the ..l.aln ..... (B)

hl"_"""

IeIbge !rom It. ~ \hI1IpI ot the MIll wIII'l grHM. Shd. the Oil .... onto the Ieft·hand end of \hi WIpu\ aI..tI !Me llultnltion 211.2) NIo check 1M cond~1on 01 the Clutctl puslvod oil seal _ _ _ II In any w.-y

damaged, W<>ffl or del....,..al..:l. or II lhetl _ I ""Y signs 01 ~ !rom H. thl lips 01 Ih. s. .1 wllh gr. .n. FIt lhe ...1 ag, ,,,sl Ih. lefI·hlnd III'\d ol lhe Input eh.1! 1_ Ylustration 211.21

s.n-

10 Mak........ both

transmiulon

ar.

shaf\$

COfTeCIIy _..:I and thIIf ....,., ponoona ore 00ff'eCtIy WlgIUad !Me IIustration 29.31 c.ulion: " baN bearin" loca l/tIfI pin • • nd halt· rin" ..,aI"..,. .... nol cOfTfl<:I/y eng. "ed, ,,,. c,..n~cal . will nol

I".

_--

....tCQnKIIy. 11 Position _ gears In _

".ho••

neutral POSItion shIIlb ... If.- 10 rotel8 fIUIly and ~Iy {Ie !he Input w I! can tum whilst lhe OUlput .nIh Ie Mid lIatiooary) and check _

......

12 A~ thl c,,,,,k~ """'" 1_

'""" "'.

30 Transmission shafts -

'!I..

dlsassembly. lnspecllOl'l

afld reassembly

ii: ~

YZF750R and SP m odels (six-speed trtm s m lsslon) 1 R~ the \fWl1lflilo8oon shelb !rom !he UPPflr erankcue (..... s.ctton 29). Alwaya d _ t I I e the lrlnan........ _n. MPW\IltoIylOaIIOid mwng up the ~

1_ 1IknItnotIon)

,/V

...

- -

....... 30.1 T ........ luIon sheflcomponenb

......

.

I s-;"gMlf-nng

23

Cl

.

2.

2'

~

2

---'

14 s-;"g MIf-nng

BIIIri'Ig 1st gtItIr p.,.;on 5thgMrpnotl

1501 ...

CiroIf:I

18 Sptocket "'"

SpinfI ...asher 7 4th gMr pinion II 3tr1(JMTp/niofI II 6ttl gfIIr p/rwotI 10 Sush /I (lu1;PUf shIIlt 12 2rId ~ pItWJn

13 .spec.-

18 Front sprodmI 17~

III Input wit 20 5", ~ p/nion 213tri14111gNr

p;o.on ~

1hrusr ..._

23 8tWt 24 6th ~ p.,.;on 25 2rId ~ p;n;on

Engine, clutch and transmission 2- 51

=

Input shaft disass embly

_

HI

Wile" dl.....mbll"fi ttt. transmission lIIatts, piKe ttt. ~ on e long rod or

IIII'Nd S ",Ire tllrollflll til .... to ...p Illam /n ord..- end 'Klnfi Itt. proper dirk/ion.

2 Remove the bearing !rom the Ief!-hand end 01 the shaft. Do not remove the bearing !rom the rlghH"lIId &lid un less ~ or the shan are being replaced with new or-. 3 RIHTIOVfI the 2r1d gear pinion from thol Ietthand end 01 the shaft ...sing a PIlI"". II will boo easler to seI the puller up wiItl the legs behind the 6th oear pinion. and draw the 2nd and 6th pillions off togethM. Note: On the mod&l sfripped c!oWIl. an lIydnlulic press WM needed to "","",ve the 2nd gsar pinion a. If W85 50 rlgIIt on Ihe wit. Take the wit 10. pmpetIy fKj<JIpp«i worI<shop if nooc8SSI1I)'. 4 Slide the 6th g ....r pinion (W nol al'eady doIIe). the 6th oear pinion bush. IlYust washer and the combined 3rd14th gear pinion off the ~,

5 Remove Ihe clrcllp securlng the 5th gea, pinion. then slide thol spline washM arid the pinion ofIthe 1Ihatt. e The 1st gear pinion 15 Integral wllh the

""" Input ahaft inspection 1 Wash all 01 the comPO"',,11 In clean and dry them of!. 8 Check the QMrtOO!hforaac~. Chipplrtg. pilling and otllM otlVious wear C>r damage Ivr; pioioo ttrat Is damaged as aueh must btl replaced With a new orre. 9 Inspect the dogs and the dog /loki!. In the gears for cracks. chips, and excessive wear especial~ In the form 01 rounded edges ( _ lIIustrationsl. Make sure mat'ng gears engage properly. Replace the palrfKI gears with new or- as a &et If rJeCeSSar)'. 10 Check forsigns ofsconng or bluing on the pink>rts. bush"" and shaft . This could be caused by o.erh&atlng due to Inadequ.ate lubrication. Check that Dllthe oil holes and pasS&Q"" are clear. Replace any damaged pinions or bustles wUh new ones. Some 01 the bushes Br\I • press ftt. 11 Check that each mobile pinion m
"""'*"

t3 Ch""k the washe", and drclips and

replace MY that are beot or appIISI _ or worn. Use new 0Il8!I ~ in any doubt.

14 Refsmng to ToolJ and Wo,lcsllop Tips (Section 5) in the Relemnc:e Section. che<::k the btoarinos and replace them with new ones

"

"...,.,.

Input shaft rea ssembly

15 During reassembly. apply molybdenum disutphlde oil (a 500150 mixture 01 moIybdeourn dieulphlde g<_ and new engirle DI ~ to the mating surlaces of tha &haft and p inions. When Installing Iha eirellps , dO not expand their eods any further than is ntICfISSary. Instan the stamped cireJips so that thorir chamf ...ad side faces the pinion it Heur.... (see Colrect fitting of a stsmped cJrclip In SecTioll 2 01 Tool. and Works/lcp TIps In the Reierenee sectlor1). 16 $Ik!e the 5th 0 - pirIion. with 1tItt pinion dog 1101"" facing sway ffom the Integral lst g&ar onto the Shall . Slide the spline washM onto the shatt. then tit the cirdip. making SlJre ~ locates oorrectly in the groove In the .nalt 17 Slide the comblnfKI 3,dl4th gear pillion onto the sIlalt with the Iaroer 4tn gear pinion facing the 5th oear pIolor1. 18 Slide the thrust washe<. tha 6th g&ar pinion bush a"ld the 6th gear pinion onto the

-,.

t9 Press the 2nd gear pillion onto the Iefthand eod of the sIlaft using • 1>''''''' or tubular drill. ref&ni"ll to Tools and Wor1<shop Tips (Sect ion 51 In the Reference Section If required. Set the pinion so that !he d istance bootween lhe out side edge oflhe 2nd gear

pinion and the outside edga 01 the 181 gear pinion (which Is integral with tha shall) Is tt8.6 mm (_ illustration). 20 F~ the bearing onto the ~It-hand MId 01 the shaft. If ramoo from Iha ~ 1t-hand and 01 the shalt using a pul~ set up behind the 2nd gear pinion 10 draw them of!,!hen r"""""" the 2.-.::1 gear pinion bush. Output shaft inspection 26 ReIer to Steps 7 to 14 above. Output shaft reassembly 27 During rallS5embly. apply m
Din

mat ing surlacas 01 the shaft and pinions, When Installing the eirellpa, do not axp""d their ends any further than Is """"""",. Install the . tamped elrellps so tholt their chamfered sida faces the pinion It secures (see ComIcI filting of a stamped circJip In Sectk>rt 2 of Tools and Worlrs/!op Tips in the Reference

..-,.

30.19 Se11t1a distance between the 2nd

~nd

1st Il"tl'" pinions as specified

2

2- 52 Engine, clutch and transmission 28 SIkle ttle 2nd gear ponion b\J$h onlO 11'4 left-hand «III 01 the sIIatI. thin aIide 11'4 2nd

WNher onto ttle shoIfI ...:I SIC... u.... with the cItcIp • ..-mg ...... ~ Iocat.. COIfICtIy In

aF1000R models

~

""""

33 ~ IN I..-.smi3sIon IhIrfIs !rom IN lIPI*' crricIM (_ Section 29). ~
prb1 onto~. F~ the t.Mng...:l CoDIw onto 11-. «III 0111-. nit u.ing a Iut>uIa' drift or P<MS I I . - . . y . relemng to Tools I!IId WO
a

$lode Itle 6th ~ pinion onto the rlghttwlnd end oj tN ahlft. wtth its selector 10f\< IIf'OO"O laeing to ttle right. Slide the 3
pinion. tN 4th ""a, pinion ami Ih .. Bplin.

30 Sb!M the 5th oe- f*\IOO'I onto !hot allalt. ""Ih I,. ..-ct... tork lI'oove facing the .,h ~ pri;n.thIn llldethe 1st goar pri)n 0lIl0

.. """.

31 At trw t.Mng onto !hot right-hand.-.:l 01 IN nil. 32 Check Ihal all componenlS haV1l bMn COITIClIy insta/led,

(fl.,.-~d

transmission)

-I Input ahaft disas sembly

:M R _ the bearing from the lett-hand .-.:I 01 the "",II t- Illu$tratIon 30.~ 00 not _ Itle bMrIng from IN rlght-1>Ind _ ....... ltotthesllatl_t..IIJ......,

""'--

35 FIImooIe IN 2nd 0 - p;r.:.n from l1'lil1liIw'od.-.:l oIIN.n.tI using. puIIr. It ... IN _ _ 'O_IN ~ "P-'1l'll1egI bthInd m.5Il'l ..... ~. _ chwm.2nd...:l $!h piorIic:n of! IOQI(her 1_ iltustrlltion) Not.: On IIIe model flnpped dt7oNn, "" hydrauIJc ~ _~ro""""""'Jhe2ndgearp/nlofl ... /f _ Ie IIghI on Jhe 5hIIft. r.,. 'lie 5hIIft 10. ptr;JpetIy~ worI<sIlopif-r. 35 Slid. thfl 5th II"' pinion (If not .1,&6CIy done). the 5Ih gear pinion buill. tm..l washer ...:I lhe 3rd II"'" pinion olf lhe _tt I"• ..... tnttloM 3O.5Oc, b and a..,.;l :)O...e(. 31 Remove the dtdip sec..-.ng the 4th gear ponoon, thin . - the opine w....... and the prGI of! l1'li sI\atI 1_ IIustratIona 3DA8c, b

....

311 lhI!l. o-I*'*ln is irItaglII with l1'li"'" Input ahaft inspection 3IJ WQh all 01 the compon ...,. In clean

, "' <:~.

"*"""t _

9 " 6,/ 2~ /", ~~)v, 2•

.. 2'

dry them off. 40 Check !h. II"' teeth I... e,acklnll, chipping , pitt ing and other obvious wea, or Gamage. Ally pinion lhal Is damaged as IUCh m ....,1N -.pIac1ld with a new ona. 41 lnapact the dogs...:l the dog hoIaIln the gears lor Cl'1Ie"'. chipS. and . xceulw aepacIaIIy In the form of rounded aog.. I'" _tratloclM 30.Il0l _ b) Make ...... ~ g.aart an.gage ~. RepiIlCe the pelted {11M! with new ~ _ a oat ~ . - y

w_

30.33 T.........1stIon ahaft ~ -~--' 1

~

lIMf_ring ",UJ/ner

2 BMrinQ 3

lS!goewpWon .fll!goewpirJon

CircIip Spline washer 3ttJ QMfplrlloo S/tIQMfpnon &.10

10 CluIpuI JhItt " 2nd f10M pirJon 12Be1orinp 13.spac.r 14 s-Ing hIIf-rirIQ "',.".,

15011... 16Fronr~

17 ~

fa SprockIt IlVt 19 s-ing 201npu15h11fl 21411'1fl 'J""'pRon

252ndgearpnon l6 BNmg

3D.lIi

u.. a puller, Of' . 1"' _ _ Ihown, 10 _va u.. 2nd gear pinion

Engine, clutch and transmission 2- 53

30,4810 SliM the 4th II"' pinion , 42 CIlICk lor ~ ot KOriog or bItMg on the pjnJona, buIJ/lla and ""alt. ThiI oould be CIIUMd by ~t,ng dUl 10 tnao.q .... ,. IubricatlOfl_ Check ' .....1 III the oiIl'IoIea and paaagea ... o:IIar _ RapI.c. any damag«I

pInionIor ~wittI '-~. SomIoIthe buIhM . . . pt.- iii. 43 Chick 'h.II\ MCtI mobile pinion moves "eel)! 00 thelhlft buI..mou. un
unlls, ttlll lIIIt.ain\J V-bIoc:k8 and I d"l IJIIlIgI and leplac. the -""'I WIth • ' - _ ~ the I'\.II'CIIII e>
30.48b, "and the "",I... wash.. onto the ..... tt ,

cr-

4l! the - - . and cirdlpaand_ any that ... bent or _ _ weakened or worn. lIM ' - on. II In ..., doubt. .e ReleninIJ to Tools end Worllshop TJ{n (c:tIKk Slctlon 5) In the ReIarance SectIon, check lhe baaring. and rwpt_ WIth ,-~II-..y

"*"

Input shaft rensembly .7 Durfng . - I I I y , apply molybdenum ~ oil II SCW50 mh
mating 'UrlK" of the ILhaIt and pinion., When Inllllllnll lhe clfCli~, do nol I .pand 1t_.-.cIa any ILWlher tlllll is r>ecessary, Install the stamped clrc ll ps SO tha1 1heir chl.mferld IId6 fKH lIMo pfnNxl It secures 1_ ComIc,

fittinQ Q/ I

,I&
.,,;J Worb'>op

48 Slide the 4th 11M" pinion. with the pinion 00\1 I'IoIM tflCin\l aWily " orn the int~ lal ~ onlO the n.tt (HI iIIu,trltionl , Slide

3O.4Ik: ' " then fit till cI..,llp making ..... It COI'TIdIy In 11>1111'00"" !hi _ _ _ onlO the ILhaft, then filllMo

Iocat.,

cItcllp, rnroklng ..... " Ioc8I1S COfTIC1ty In the II'QO'>'e In the IhItI: 1_ iIIustrItIonaI. ... SI""!hI 3rd gaar pinion onto !hi wfl with It. Hllclor fori< groo-.o_ IKIng the 4th 1IM"p;r.w. (_~ _

flO SIIdI ItIII Ihnisl w_, the 51h ~ pIniorl bWI arod the 5th IJ8IIr pIniorl onto the IhafI 1 _ 1I1u11r1t1onA) 51 Pr-.. tlMo 2nd IJIII" pinion onlo lIMo lelthIond end oIthelihafl using a prna or lubuiIr drift, ..f.mnglo T<>OJ$ Ind Wor1
the rigIII-tw'd~. using I ' - one.

2

....

. Ind ltIII 5th II .... pinion onto ItIII

3O.lI1 .,' t"- preas on the 2nd gear PnIon .. describId

30.52 FIt the bIIring ...,to the 1If\-..... nd _ofltllllhal'l

2- 54 Engine, clutch and transmission

53 Check Ih.1 ~I components have bMn c:orr.etIy Intl.-llld 1_ Illustration).

Output ahett dlsalllMlfTlb/y

Output lhatt (nlpeetion 56 ReI.- 10 Stepo 39 10 46 aIxIYe. Output ahltt reassembly

54 ~ I'" ~ trom !he righl-Mnd end 01 !he nlt 1_ Ilu.tratIon :lO.r;:JI. 55 SlIde !he lit gMt pinion end Ihe 4th gMt pnon otIlhe righI-~ end 0I1he Wft 1_ illustrations 3O.e2b .nd .). 56 Remove lhe clrcllp. then Ilide I'" Ipline ww.., Ihe 3rd gear pinion and the 5th gear pinion off the Shah 1_ m... 3O.e1d, c, b.nd I). 57 ~ Ihe Sj)IIC«. beerinQ.nd 2nd gear pinion from Ihe '-It-h¥ld oIlIMt shaft """"'iI • puIIa- HI up behftd thII 2nd oe- pinion, or • ~ to 0-- tt.n 011". itlen rerncMI!he 2nd gear ~ buill ( _ IlIustrltlonj.

58 Dut1ng 1'IUSIO'I'lbIy. apply motytld«Ium diIuIpNde III \II 50150 mbo:tIn of moI)1ldInI.wn diaulph!de "'.... and new engine oil) to ,'" mallng surlaces 01 I'" shaft lind plniona. When Inllalling lhe clrcllps. do nol e~Plnd their IndI ~ further !han Is necesswy. Instal the I tlllTlped clrcllps so thai lheir chaml..ed .JeIe laces the pinion il secures ( _ Cotract fitting ot'$t~ citcIip ... Saclion 2 01 Toots ftrd WotQhop 1f!/I ... the Aef-.ca MCtion). 10 Sl~!he 2nd gear pinion bush onto .'" '-It-h¥ld end 01 !hoi shaft, then oIidtIlM 2nd gMt pinion onto II. F"~ 1M bearing end ccIar onto !hoi end of !hoi shaft using • tubueIr drift

3O.1b SIidII tIM 4th ON!" pinion •••

3O.02b ••• lind tIM 1st IINf pinion onlO tIM

""tion,

....",

...

or pr-. II necessary. referring 10 TOOotI and Worb/Iop T/p3 (Section 5) In !he ReI.1IOCto

s.ctIon M~ 1_ -...tratIon 30.57) e1 Slide I'" 51h gear pinion onto !he rlghlr..nd end of !he shaft. with Its Mleclor Iork groove ,.... "11 10 !he righl 1_ lHuflflllon). Slide lhe 3rd gear pinion lind 11M Ipllroe WMh. onto IIMt shaft lind eecUl"l them with I'" clrclip, makir'lg SUM it ~I" COITtdIy ... Ita groove 1_ ~Iustratl .....). e2 Slide lhe 41h lIfIar pinion onto 11M sh,ft,

wllh II, aeieclOf 100<. groove laCIng 1M 3.d gear!*lion onlO the .,..1\ 1_ Mlwtratlons). &3 FIIIhe bearing onto the righi-hind end 01 the IIhafI 1_ Wlwtratlon). 114 CMck Ih'l .0 com~ .. hav. bMn gMt pWon. lhen slide lhe lit

--.

30.83 ••. !hen fit tIM baaring

Engine, clutch and transmission 2- 55

31.4 Note the leu. on ..a. fork denotIn& Ite poeitIon

31 Selector drum and for1ts-

removal, Inspectk>n and installation HoI.r. To,.,.,...!he...r.ctcr <Svn.-J Iorfa !he ~ mtQIt be I'eInOYed hom lIN frame .-J Ifw CtIInIrt:a!oII'IItII'a ."..~.

Remolfal 1 R.....,.... lhe WlgI.,. from lhe frame (1M Section 5) rod ..,*"lIe!he ~.­

(.- Section 23). :z Hnat """-!y dont,

fWTlIMI

"*'""""" 1_ s.ctiOn 201.

the ~

3 u~ lhe DOlt wtlk:h IICls . . the _lor drum ........ !_ Mlustr.tion). 4 Belore rerno-.Ing the Hieclor 1orkI. note 1t\at~forI<"letI..-Ifor~

The

I"IghH.end fori< .... an 'R'. the C«Itr. fori< e ·C', and the left·hand 1M an 'l· In ....1rlItIorl). TheM 1elt8f!J lace 11101 riQht-1Iaod lIde ol th .. Wlglne. 1/ no ifill .... are ~+1I lb"'. ""'" 1htrn yourMII UIIng e felt pen. II Support the MIt<;tor forks rod wiIhIhw the ntI from the casing. IhIn . . . - \hoi forb 1_ IlkRtr.11on1 Once from the ceM, -.Ik!e I'" lorn back onlo Illeir 1IIIa!! in theI. COITfICt order and the right way roo.nd. e Withdraw t... Mlector drum from the righlIIInd .... "'the ~ 1_ u...tntIon).

I''''

._Itd

Inspection

"""" 1 bM1ng ~Isl belore t>oyW>g 1 ' -

1 Inapect the Mleclor lorI<s lor any alg-n' 01 wea. or damage • .specially ••aund 1M lOtI< ............ Ihey ~ willi thegtOOYlln the pinion. O>ed< thM ~ Ior1< IiI3 corNC1tt in Ite . - - , grocMl. ChecIr. dOMlly /0 _ N the Ior1
drum . A'-o c hllCk Ihll the neul .., s wilCh conlacl pIuroger In the OIh1f rod 01 the drum .. "" to ,,-In end out ....... op+.g~. It ,...,lfltd. remo .... the securing 1M contacl pIIte end _ tM plUIIO"" and .,:>ring lor Npecucn or .....-I.

, The Mlector fork lilian. eM be chIoCked lot

13 ReIer 10 Slep • lor the correct location 01 MCh fork 1_ III1.mr.11on 31.41. lubricate the selector fork llllaft with clNn tngjne oil, t..... slKSe It InlO lhe cranl«:ue and th.ough 1M Iorb lind Into the barto. making . . . the Ior1
-

10:._

Installation 12 AI~ the ","""",or drum .., lhal lhe MUtraI del,", ~ to the bottom "'the ~ tOO slide the drum Into the crankcaM 1_ ~31.81

I I " - . by roIIlog them along. rtat surlace. A benl rod will C8UH difflcu~ in selecting gean "nd me"" the srearch ang.oo IICIion _vy. RepIeo;e the ~ wtth ' - ..... It benI-

10 lnapect tM MlflCtOf drum groo_ and Mlec:tor fork guide pl.- for signs 01 _ or d"m.sre. II .. ither thow signs 01 WIN' or damage they must be replaced with . - ...... 11 Ctwc:k th.1 the Nlector dru m bearing

roIa_......,,_ ....

noo.igr-.."'~

or UOIeIive IrMpI8y ~ ~ tOO the drum or crankcase (wI"Ien lnatlllled) IsM T«* and Worb/IOp TIps (Section S) in lhe Rei.......... Section for more In!o.matlon on bearings). Replace the seleclor d""" w~h • new one i! nec;:eNl'Y - the bNoing Is not a~allabltl MI*'8I~.1hough M_lAd be WOO'Ih checI
--

31 .1 WIIhchw the Mlectordrum from the

iIIII'IItr.tlonl. 14 ~ .....table non-permanent Ihrud lockIng compound 10 the seleclor dl'Um "'til... b<>II .,.., 11gh1.., II to the lorque seil ing speellled al Ihe begin ning 01 Ihe

Chapt_ I_ ~IUS1rll11on 31.3) . IS Raassembl .. the c. ankca ... hal_ ( _ SectiOO 23).

31.13 Locet. the """' ... on..a.fork Into Its groove In the drum

2

2· 56 Engine, clutch and transmission

32 Alternator/starter drtve anembly - removal, rospectlOO and installation

~ ~

~

--

Not.: n..s. c:omp<>t*Il$ con only 1M ..:e.SHd .fffK ~nltlOl'l 0/111" cnIllkcow

Removal 1 Remo •• Ih. engln. 1- SlICIion 5) Ind MOp.." . Ih. c.. nkcase hatves Section 23). The all.-nlliOf drtYI shafl. start. clulch and idle g .... UMI\'"IbIy . . all located In lIMo upP« MIt 01 lIMo ",_ease.

I'"

:2

R_.

s.:uon 211!

pope"

ttoe trensmluion shafI. (1M AlIa .....,.,.. the . . nozzle rod W

r-.quIred lor Imp'o.....:! eccesa the o/t

s.ctoon 24).

~

3 Wltlldrlw the "arter idlelreduchon Q6II" ."." «Id .....,.,.. !hi gew t-1IustrdonI • Unac..w the Ihree bolts HCUrIng 11M .nem.tor drive -'>all r-ing retainer ~ to the erenl«:ue lind ......."... the plate 11M

-.

"art.

15 Support 11M clutch. theo w'ithdnlw tIM burtng lind the drive sheft from the crankCIIe (1M lllullr1ltlons) . If the belting II a light ,~, UN. alicH-hammer with aultlble en!I-edapt. to wilhdraw the shalt IOd bring It1ebNmgwittl~.

fI ~ the I-iy-Vo chain from the slart", clutch IIOd .....,.,.. the stM ", clutch from the CfIInkel.. '1M m""t..tlonj.

7 " .equlred. remo.e ttoe etanks.hl" (1M Sectoon 28) and d~ the I-iy·Vo chilI"\. u..ctaw the bob ....:umg !hi chain ~ 10 the c;:r~ IIOd ,.....,... !hoi guide. notln5I _ WWof fUUfId MfilL

3Ub Check the operation 01 the clutch . .

"-'-'

Inspection II Withdtaw thould be

"art...

...-

Engine, clutch and transmission 2- 57

--

1() Remove I~ roI .... and checI< In. ~ caps I01d spmg. tor Iigr-. 01 doIt::ormoobon ...

lIghtll'l tham ~. lnatlllthe c .. nItshotlt

~,MlIke .....

( _ Sec!Iott 281.

II

!hI1*' ~ fI'eIIIy In its

ChecI< that \he three AJJen bo ts

secorYIg

1I\e starter dutch ~ togolIt. . . light. If IInf I .. 100M, remove au I~ boItl. lhen Ippty I IoUrtae.. non·perm....." thread Iocklnll compo~nd Ind 1I11hlen Ihem to the lorque INI1'ng spee~1ed ., t~ IMglnnlng 01 !heChlpl•• 12 !he t.. th of the Idlelredvcllon lI..r aoo the co""ponding leelh ot the st.o. CI~tch gur and st.rt... motor gaar. Renew \tIa ge.an; .. I worn

Exam'....

or~toe(h",~"",

".0'"

set.

13 Inapect the . ~Im.tor driwo shalt and Its baarlngl (one on the shalt. the OIIM< In the cnnIeII. HHt Iha area arouoo t~ bMrIng In tile cnnkcua to

_1Is....-at IN- -.&01). H!he"'" _ _ . . worn or dImIIgad !he Wft must M replOKed WIth I new one. ChecJ< at.o the Cortatpondlnll apt,nes in tM Stlrt... dutch, _thcMontheHy'Vo_~Wft.

,. The Hy-Vo chain and 111 II!MM In the crankClM can only be Inspeeted proparty liter tM cr.nk.shalt has bMn r.......... ed (_ Seo;tion 31). CI"«IIthe Hy.Vo chIIn 101d!hl chIoin II'*N lor IIgN of _ or dI.-n.gI. I01d repl_ w,th a new ona II IIK""'Y 1_ Illustration). A#t I auitabIot non-permIIfIefrt tI"nId IockJo"og ~ to \he b o I t _ and toghtlll !ham to the torq<.a setting specIIied ., the ~ 01 the Chapt._ Also chllCk thl Hy-vo Chlin sprocket and thl sprockll on \he CIII\kshaft lor IIgns 01 _

«-

Installation 15 If fII'I"IOVed. InIt" tt. Hyo-Vo dIIIin guida !hi cnnItcaM, InIIdng ..... ~ Is 11>8 c:orracc WI)' fOU"\d. AwI't • IUlt~ non·~t WI

Ih,eId locking compouoo 10 the bol1l and

18 l.-t the .tart... clutch In the crankcase and engage t~ Hy-Vo chain on the sprocl<eI 1_ illustration SU). 17 Suppotting the st..,. clutch, " - ' !hi all...,Ilor drlva ""alt through the auembly !rom the ovtaIde 01 the crankcaso unlit ~ __ fufly into the bearing In the crankcua ( _ Illult ...lion 32-5b). fit 1ha baring onlO 1ha I01d 01 the shalt. making ..... ~ Is prauad fully Into the C'lnlteRM Ilaa IItustrltlon 32.51). Apply a sultabM non-penna.....,t thread IocI
Insta ll"" ...embly II •• .hOwn Is" IIiUltrltion), Insllil the !fan.mlNlon shaft.

OM'""""''''

32.13 Chack tha IMIIIing

_t 110 houIId In

"'-

and makl """ the transmission _ contrail, eepaciaIIy 1M brlkeI. func110n prop.rIy bafore road twtlng the rNICIWIe. RaIar to Sec!Iott 3( lor the I . . . . . . . w.:Iotd",.....;ng.Jn~. 8 Upon completion of the roIId ,,,'. I01d 1ft",

the engl". has cooll(l down complatet~. ~!hI ....... ~ (Me Owpter 1) and cMck lhe angina 0II11ld ~ ....... (MaDto/ijl

~

ChICks).

34 RecOlTll'l'lltnded running-In

33 Initial .taft-up after o....rhaul

-~ 1 T","hemac!Ma IIII'IIIy lor tha firlt law

1 Make &UI"8 the angina oil tevttI anti coolant

,..... . . ~ (Me o./Iy t--tJdeJ choocIcIl. 2 "... ...... IhInt.fuallnthetank,IIwIUn 1I\e lull tap to \he 'ON' ~ion. and HI the

--

3 Start the IIIII,ne and allow h to run at I modarlle1y ,. , Idle untY II ~ """"II

operIIttng ~

. .... no 011

~e warning light '- fitted, en 011 presaura dlack mult ba carrMod out (_ Chapt.'). 5 Cr-k carafully 10< 011 and coolant laeb

32.1. The Hy-Yo chain tuIde Is HCurad by two bolts 1....owadJ

mllal 10 make IoU.. .,;! hiS circulatacl Ih""'llhout the enilio. and any new parts Instdad have started to ..t. 2 e.,.., gowt. cara II ~ Hlila ..... hili t.e.1 e~tll'l~ ~ulad - t~ billa will hlv, to be run In •• when new. This means graIIl. . . . . 01 the tranamlstlon and a fMtraonlrlg hard on !hi 1hrottIa until ., Iaas1 SOD mIl. . (1000 km) ha ... bMn coverad. There'. no po:Wtt In ka.plng to any HI IIPI"" Umit - the main Idea Is to keep ~ the engl". and 10 ~ually incr.... parlonnanca ~p 10 !hi 600 mile (1000 km) mark. TllftM recommendlltklnl apply IaN

"om

2

32.'" The Installed .... mbly "'oold be .. lhown

2- 58 Engine, clutch and transmissioo whIn 0ow, Il>ough it <10M ~ 10 _0 exl.,.,1 on the 01 II>e work carried out IOd Which ~ IwYe bMIl..--ed. ~ _~. ~'. -v 10 lei whIn all engine is running •...-y.•1 In "'V doubl. contUit a V."",h. (l.ea ..... The mU'mvm engine spHd IImlllllonl (..... labIH), whlcl> V......., proyIdio for new ~..." btl

",'ur.

.1tIIo

__

"fZF1tsOR -.d SP Up 10 100_(150 kmj 100 10 300_(15010 500 km) 300 10 eoo rriMosl:.oa 10 1000 km)

10- eoo ITliIes (1000 I<snI

UMd_.~.

3

N.~

....... ~ltOpthe

1I'Igirwirr'lmldill.tylndtrylollrldltllo~

N..

.-one ....... W1hovt 01. _

I*iod 01 _

lot • I/'IOrt

• .....- damage wII OCC\.O".

}'U.""""

UpIO 100 mikIos 1'50 kmj 100 10 300 miIe& {l50 \0 500 ~ 300 10 eoo "*- (500 10 1000 kmI

10- 6OO ...... (loookn;

""'-""'-7500""" ....

...... __7000""" ....

V~ ~

poeIUOo'hpooed. 00

lIOI ..... tuI~

':':~=~OO

....

..

V~ttvotI!e~.lJM

lull Itvottle IOf ohort bursts !"'~~

VIry1lvoltla~.00

~"'poaI\lQnIapMd. 00

V~ ~

..

v.yllwoltl&~.u.

full

~

lot thOr1 bunIts

"'~~

...

Chapter 3 Cooling system Contents CoaIn r.:... _...,;I ........ - _ _ and InstaIIMIon 9 ct.cI< . . ...... _ o.iIy ~) ehecb ~t ~-remcw. and iowtallatioo . 3 eoo.nt t~ gauge II1'I
eo..m ......

Degrees of difficulty

Glnwllilnlonnaloon . Radiator pr-..no cap - ehIock • Radiator - _ _ and instaIIatiOtl .

-. ..........

~ta\

t.ous;ng _

WI' .. putnII -

~

~

,,,,,,,,,,ai, _

- I'WI'ICMII. choIck..., IIOd bNring rwwwal • .nd

Specifications Coolant MkIIn Iypeand ~ •.

_Chaplwt

Radiator c.., ....... O!**'II pr-...

13.5 to 17.8 PIi ".03\0 1.23 a..j

Cooling fan switch CoolIng Ian cui-in t.npenolure .

102 to tOO'C

CooIn5IIan all-out tempIrIturll

"'0

.........

Coolant temperature gauge sender VZF7SOR.-.:I SP .......

....e

o 100"e

""''we ',oooe

n to 58 om.. 26 1029 o/'wna

Thermostat

,"","",'....

891073'C It mm (min) 0 M "e

~

Torque wrench settings CooIng t.n ~ . CoolIng tan .wilc:h

--~

te
n.mo.tat"""*'ll ~ __ ........... "•• . RadIator mounting boItII .

10Nm

Wat ... pump bolla . wa.pUmp __ . ~lnIeIunIon~~bIocicbolts .. ~I

ootie1 union to cyIIoder hud bolts ..

1 General infonnatlotl

form 01 hat.. 11'11 cyIindoIrI . . IUITOInled 'Dy • _ _ jacket from whk:n Ihoo heated coolant

is circulated by Ih«mc)-Iyphonk: acl~ In with. _ _ po..mp. do'-' by tt. ~

• wat.,aot ....Ml.. cooIaIlt to carrr away .~ceaa -IIY in the

Tha cooling .

Tem _

3

,,"'m '''''' ,,",. ",. ,,,,",.

oil pUITIp. The hot oocIMI ~ uPWarclllto thl Ihenno ~ t .t and through to ttle .adl"or. The coolant n- now. ~ !he ,adL.tor

c:cr., wi-.. R 110 cooIad bV !hit peIIIIng air. 10 thfI wat ... pump and back 10 the engine _ _ the qCIe illWIlMtod. A tMrmostllt II; liHIOd In the Iystem to I""..,t t"- c;ooIant tIQwIng thfOlJgh th' radlatQ< _ ~ating

ttlll ""lI1 .... hi cold, There/ora opead It which thll .........

tha

3- 2 Cooling system rHCIIn normal oper'8Ung temperatUla, A coolant teml*'ltUri Mndllf mounted In tile rldlat", tran"", ;tI to tile tllfnperaturl g.&uge on tha Instrument pol.... . Two t hermostMically-<::Olltroled cooling f _ I n flned to aid COOI'ng In a xt,...". cond~iOIed by • valve contIIir.:I Inlh
A 1

t,..

,.",o~a

Do "01

W.rnln,,:

pnasu,. c.p lrom tha

I1Id~ lor

when tha en"",. '" hoL Scaldln" IIot cooIanl and . ,..", may be blown (NIl ..... -. which oouId ~..",.,. /InIuty. _ _ tNt;It"",,_a~

antffrll-la

COIItaln.

COfJ'O.1On

I,..

PIssages, ,..ulflng In ovem.afln" .nd • ........."lna ~m~. Dis tilled w"", must be lINd a. opposed 10 lap wal ... to aoroid athebulId-..,:t '" acaJe which ....oufd eIao _ PI"",,""

1 W pro/:IIemI sud! _ ~b/Ig '" 10M 01 cooIanl occur. chack lhe entirl ayst"'" .. described In Chapt.,. I. The radi"or ~ap open ing prlssure s hould be ~hecked by • Ya "'ah8 d N~ with lhe special IMter r.quU:I to do Ih
....... _~~

w.,....""'1"_

Removal t R8moY8 the _

and the rlght.1\and aide

coY . . (yZf 1000R models). aIdII coYefI (YZf75OR .....-jor_ ~ (YZF75O$P 1TICIdaIs) 1_ Chapter 8).

2

Re~ase

tile

cl.mp

~ecUl1ng

lhe

CwUon: At all ttm. .... the ~ ()'pe a"tiIrea"., and .lwa,09 ",ill II wllh dl, tl/led .... , er In Iha """",,I proportkm.

.adlator ov..tlow hoM to tile be.. 01 the r",""",oir ( _ Illustration 3.2). o.t.ch the hoM and a llow lhe cooIll'lt 10 dralll 11110 tile cont8lner.

antHr.eze ,. dI6pt..J ",..,."..

01

~

~

Cooling 'an Chook 1 " the engiM It """"-ling and the cooling lana areo'l coming on. liml oheck the coo4ing 111'1 cir<:ull !liM 1_ Chapter 91 Ind than the tan swilch .. d...,rlbed In St.~ 8 to 12

-

.nr...

II dMcrlbed In ChIIcI_ 9 3 To tnt the cooling fan mot .... on 1993 and

".... til"

_1ot;aI~a(Ioout~"'_

$'

connectlDna

t>r.alhllr/ov«f\Qw hOle (com"", OIl! ot IIIe lOp 0 1 the r...... olr) end detech th. hoM (, " illuslnltionj 3 I'Iaoe • MlItab18 container ~Ih the _ . 1Iwl ........ 1he dImp..:ulng the

anlllrNze. Many _unItfN _ coIIec:tlotl c:en1tN wh/eh _ _

SUre the hoMI; ... correctly ,"-laDed and ....,...., with thai. I;\amp'-. On complation . - the _ . . descrIbad In CIIept.- 1

2 W lhe f ..... do not _ on. land IhII fan switch ,. good), or only ..... oIlhem t;OfTI8$ on. the htuII: ,.. In the cooling Ian mol ... ... tile relevant wiring. T_t" the wiring and

3 Coolant reMI'¥Oirremoval and installatiOn

.'_t,.. m

Donol ........... ~to _ _ """'_ w/lll your sIrin 0.- paIn/ed surt_ 01 I'" ~RinMoIr..., . . . ~ wilt! pHlnty 01 Is hiIIh/y /oIIJe IIIngoosted. ~""" .... _ /yILoIg IIfO
Instllllation 5 InstaIAtIon It the _ _ 01 ___ . Make

Cooling lans and cooling Ian switch check and renawal

""""

IJowfy rolll. I'" ClIP anll-cfoclnriM to the lim ,lop. 11riII~a/bn_1UIduaI pn"u,.. 10 a.".pe. Wha" t". ha, IIoppad a~ pre.. do ...n 011 cap

"""1wnInsi' If .... ~ aod .......... 1t.

1._

.. Uf\8CrlW the ........ olr moun""" ~ Illustration 3.2) and ramova Ihe ....-voir. noting how ~ ~ts.

2 Radiator prenure cap -

a

e

o

a

I

p

;

I

-

"

"

"

"

"

_

~

-

TIll

Inhlbllon wh/eh a,. ...anllal 10 a~old dama"a 10 Ih. coolin" .,sla",. A lac~ 01 Ih ... inhlbllOla could lead 10 • build-up 01 corrosion which would b/oc~ cooIanl

1994 YZF750R and SP modeIl . '''''<>Va the fuel !.Ink end air M.. IIcusir1Q (_ ChJpI.. 41 ~ the fan mol ... wiring COfW'oIOCIOrI . . Icc:ated ' * - the coila. w-:l 01 the CIftIweIItn. On aU othIIf mcocMla. .emove thll IKiIIg _ """"'" (_ Chapler 8) - the wiring COfV\eCIOf /of each fen • Iocaled ebowl IIIe end 01 the radiator (_ Illustl1lllon). Tr_ tile Ian mot'" win"" and diac:onnotct ~ 8t the COIIfIICIor for the fan baing "'tad. lJsIng a 12 vol! NtI.,and two lU",par COI'II'IKt IN ban.,.... ds to IN I... wiring con"""or, Once connected the Ian shoukf 0parlI1 • . " ~ doN not, and the wiring . . . good. thin the I.... laulty. Individual COITIpontInIs . . .",,11/IbIII for

WU"_.

IhIIfilii u ..... bIy.

Cooling system 3- 3

•. 8 OiKOnneCt the lIn l witch wlrtng connactor twrO¥Md) ~w.1

A I

•

W....I"Il' TIl. "'11"" m.... ' H c.....,.,.,./y cool "-fore urrylnll ouItII~ ~

t"'-..-diaI« (_ s...tIon 1). 5 Unsc.ew the th.".. bolts M1Cutlnll the ~~nt f~n assembly to tlMo radiator. notl"ll anv colLa.. or clamps IItted wrth them. Ind .-nove 11M fan 1 _ MI .... tnltionI. Il In.tlu.tlon I. the .......... 01 .emoval. TIght.., !he boIU to the torque Mltl"ll ~ at ItM btgirIr.-.g 01 the CtwpI. 4

~

Cooling 'lin switch C..,,, 7 H 11M engine II overn.ting ..., the QOOIing lane ..a.1't COI'Tllng on. Int chacl< \lie cooiL'Ig laro ~I'<:Ult Iusa (.... Chapt.. 9). II the II.>H is blown. ctlacl< the fan ci'CYII lor I ahort 10 earth 1_ t"'- wlrlng OLagtarntl .t troe Iond 01

....

-

Il "11M II.>H II good. remove 11M rlghl-hand fIIMg IidI par>eI (Me CIaptw It. o.eom.ct

the wiring connactOl' from the I... IWltch. mount.., ... 1tM II'ont 0I111e I'lICiatoI" MlocMIIIM ~u.ge MIIdw t_ Illustration). USIng I JurrII*' wire. oonnecI ~ t"oIlfIrminIII WI tile witlng connec:tor. Thtt fan shoold 0;0..,. on. II tt _ . the f... ,wnch is del"ec1""- ..., m",' be replaced wllh I new one. ff It dOH not come on. tlMo fin sho<.Ild be I~I"" (Sle Step 3). Q H the I... ''-'Yfo on l1li lIMo Itt"ne. disconoIct Iha ~ comector. The f... t:ht:Utl stop. Nh does. the iJWItc:lI 18 deieclmt and musl be

"1hIo

"""""' .... WIlli I NW ..... Ian doMn'l "op. ched\ lhe wiring bel_ the switch ttndlhlo Ian. InC! 11M fll'lltsell. 10 If the fan work. bul Is suspected of

cuning In al lroe wrong temperatu ..... more comprehflnsi" IHI of the s'l/~ch can be mad!tu~.

, I AfImo:>W 11M .-M\ch 1_ $I00I , 3..., I .), Fi" a IImIIII hNtprool CO"taI_ with coolant ..., ~" on. stove. Connect the probea 01 an otvnmet. 10 lhe I. . . . . . 01 the SWItch.

and USIng

"*

wire or other support suspend ItM MItd'I in ItM """"'-" so Ihet the ......... portion and II'MI t _ 1 are submerged 1_ IIlul tration) . ""so pt_ I Ihen"non"oMw capable 01 reeding lemperal...... up to tt O"C In ItM _ I "" lnat II. bulb II c kl-!! .. 10 Ih .. swilch, NOlI: None 01 lhe componetl~ shoold be .llowed 10 diraclly toucIt the contli1lr 12 Initially II'MI """""-,,,, rea
A

10I"I"II

',,"r

u...,. ..

. . difterwtt, or obIM'Ied at different I .... peraturetl. then tile tWIt"" II flulty and _t.~witI1

•

..w_.

Renewal A W.m/nl/: Th• • m.,51 be compl.llly cool "-'0" C.l'J)'inl/ out III,. procodure. 13 DraIn the cooling systemt- ChIpt... I ).

"gi".

ili

'*""

I. Remove tI'MI rIghI·hInd fli1ng IidI ( _ Chapl.. S) OIKonnec:I !he wiring

COrYIIICW from !he fan MItd'I. mounted in !he fron l of tile ,1td"10I' (. . . 1Il.,ltratlon • .1)

Un..,r_!he swtlch and _

It lrom the

rlldialOl' ( _ IlkostrMion)

-

15 Apply ....itll>le _11,,1 10 lhe .wilch IhfIIIds. !lien II'MI ,wi\Ctl and tlgtlten ~

.,.,,11

to th .. 10rqU.. ",ltlng specilled al Ihl blglnnl"1/ oIlhe Ch.pl .... T,ke car .. rIOt 10 ovartlghten tlMo swilcn I I 11 or lhe radiator

.....

11 FIeo:>:tnnooct!he~~""..riI!he

~

syst.... ( _ 0'tIpMr

n

3

0'

, u .. 10 1!IokI I~ ri,t • "..--lIlnjufy. When the 1....1*111...... ~ artu>d 102 to

I OS"C the met ... ,. .ding should drop to

4 .11 F ....whch ...tingNl·""

around 'tWO 011,",. lndW:atlng tIlal lhe t wllch has closed ('ON1 Now lum the heat oN .... the temperature 11118 below {wC \hI mel ... reading ahould Ihow Inflnitl (very high) WIOtcatlng tNtI tl'Ml twitch hal opened ('OFf'). 1\ 11M _ .-.gs obi....,;!

resIsI.....,..

• . 14 Unscrew .... IWItch UIhg • IUItabIe spanner on ......... (--.d)

3e 4 Cooling system compOll.nts should be allowed to dire<;tly touch lhe cot"!!al/"l9l'. Heat the coolant. atimng ~gently.

'*"'*

A. ili

Warning: This must be very cara/ul!y t.o a~old tile rlslr of perso"a/l",ury. When the lemperllture reechat! around 8O"C the meier read ing should be as spacifled at the beginning 01 the Chapter. When the temp8nltUf8 reaches around l00'C the meter shou ld again be as specllled. If Ihe met .... readings obtained a,e different. Or they lire obtained at different temperatures. then the Setlder is faulty and must be renewed. Renewal

5

Coolant temperature gauge and sender -

check and renewal

A. ili

~ ~

~

Temperature gauge Check 1 The circuit consists of the sender mounted in the radiator and the gauge assembly mounted in the instrument 1*'81. If the system malfulK.';oll5 check fi ",t that the batte!)' la fully c:I\argI..d sod thai the fuses are all good." they are, remova the righi-hand fairing side panel (see Chapt'" 8). 2 Disconnect the wira Irom the sender and tum the ignition switCh ON (see Inu5tration). The temperature gauge r.eedle should be on the 'C' on the lIIuge. Now earth the sender wire on \tie ..-.gi ...... The r.eedle should swing immediately over to the 'H· on the gauge. Cautio", Do not earth the ""Ira for any 10"(lar than II "aceual)' to talra tha or tha "auf/l may be damllflfld. II the needle moves as described above, the sender is proven defective and must be replaced with a new one (see below). 3 If the ~Ie rnov9fTMIf1t is 5tll faulty, or if it does not move at all. the lau~ liM In the w'ring Or the gauge itself. Check al l the ra levant wiring and wiring connectors (see Chapter 9). II all appearn to boa well. \tie gauge is delective sod must be renewed.

_"(1,

Renewal

.. See Chapter 9.

5.8 Tamperature gau.ga

~

toostlng

--~

Temperature gauge sender Check 5 Drain the cootlng system (see Chapt.... 1). The ".,nd .... is mounted in the Iront of the radiator on the righ t-harld side. below the Ian switch. Remove the right-hand talring si
e

(see Chapter 8).

Disconnect the sen
(see Illuatration 5.2) . Using • continuity lester. check lor continuity betw ...... the SBfIder body and $Qrth (grOoJnd). Thete sI\oukI be continuity . It lheffl is no continuity. check thot thtI send .... mounting and the aarth wire below it ara secure. end that the earth tlllfTTlinal is clean (see ilkntratlon 5.2). 7 Remova tha ".,nde< (s"" Steps 14 and 15

""""I·

8 f ill a amall haalprool contain.... with wat .... and place it on a stove. Using an ohmmeter. conoact the positive (+ve) probe 0 1 the met.... to the terminal 00 the sender, and the negati ve (-va) probe to the body 01 the sender. Using some wire or other support ~ thtI seodoer In the coolant so that just the sensing portion and Ihe th reads lire submerged. Also place II thermometer capable 01 reading t,,",~atures up to 11 erc in the water so that Its bu lb Is close to the sender (se. Illustration). Not., None of tile

Warnln", The ."glne must be complelaly cool before carry/fIg out this pmcedu..,. 9 Drain the cool ing syslam (see Chapt.... 1). The ....n
....

Rel i~ the cooling system (see Chapter 1). I""tan the fairing sida panel (..... Chapter 8).

12

6 Thennostal noosing ~ and thermostat .;z removal, Check and installation ~ 1 7he thermostal is automatic In operation and should give many yea", service without requiring otlantion. In the event of a failure, the valve wil l probably Jem OPOHl. In which cllse the engi ne will laI<e much longer than normal to warm up. Conv8l"S~y. il the valve Jams shut. the coolant will be unable to circulate sod the engine will overheat. Neither oondltion is acceptable, and the fao~ must be investigated promptly.

Removal

&. ,

-

Wllmlng: Tha engl"e must be complet.ly cool ""0.., Cllrrylng out this pmcedure.

Themtostat housing 2 DnIin the cooling system (see Chapt .... 1).

5.10 Unscr_ the sender using I sultabl. span ..... on the hex (arrowed)

3 Remove the carburetlors ( _ Chapt ... 4) .. Slacken the clamps securing the coolant ho".,s to the thermostllt housing and the outlet ""ion on the cylinder head and detach the ho".,s, noting which fits where (.... illuatrationa). Unacrew the bolts eecuring the union to the cylinder h""d lind remov~ the I...."on and housing together

Cooling system 3 e 5 Ihermo<Stal .. faulty and must be replaced with .-~ 11 In IhI _ I 01 tt..mo.II1 fllllu ..... In _1IIfICY " - ' " aNy. II CIn be...-.d and the n'IaICI>Ine used Wlli"o:Iut II. Note: TMe C¥I wilen .Wflllg fill angina from coki loS It "'''''I7IUI;II~IlWI'''''!o_up. ~, tI\at a ' - In\ lIin1U11ed .. 100I'I . .

,..-

InstallatIon ~stlllt

n cenyIng

OUI

"'*'

~ tilt. If ~ _ _ In tr. room lemPl"IUI". ~ IIhouId be

5 II requIIwd. """""_ ~ bolts MC\IVIO ~ twuSlng to the union Ind separltl them

poaItiOl'l ~

0iKard~0-1'WIg

~wl\hl'-_

Thennos~

10 Suspendlhllll'ler..-Wbyapoe(*ot""... In , conlalne. 01 ~old "".Ie •. PIICmeIIr In lhe ....1. 10 Ilia! tr. bulb II close 10 tr. lhermo&tll 1_ ~lu'I •• tlonl HMt 1hI_1r. noting IIW I .............. ~ the ~tal opens. and compar. the result wtth lhe specIIIeations IIlvan al the ~ 01 IhI CI'IapI •. Also check thl IITIOUI'lt lh1 . . - opens aftIr It ... bean '-eel ~ 8S"C lor I , _ .... nuI.. and compete tI>I measu.ement to Irte lpIe ificallonl. (f lh1 reedIngs obIained dIll.,. from thole 11'->. tile

I Oo>tn ~ cooling system (_ Cl\aptlr 1~ 1 fIernovoI ~ lull tanIr. (_ Chaptlr 4) II UnIcrew tr. bolts MCUrIng tr. ~ housing cov.r Ind Mj)Iflt. II lrom the IIousing (... mu.,•• ,lon) . Withd .. w th. tn ...""",t,t. noting how It ,,11 (••• 1IIustno1lon).

Check II ExamIne the th ... mostat visu.lly before

housing

ltlstailabOrl II the _

new

O'ri~ and

of ..."".... Usa

am..

tllem with g'''5II. nolllen the ""tI~ un\on bOlta to t ha ,,,,,que Htt"'ll specified at \!'II beginning of IhI CMp... MaIw ...... the ' - ... pushed IuIy 01'1 to ~ . . - and ... IIICIQd by tr. .........

1_ YluSIII',onll.", b and c, or 1.4d). 13 Refill the cooling s~tem (_ Chapi.. I~ Them>ostlilt 14 Fn IhI thermostat kilO the twuslng. .....,ng ...... that II .....u corrwctIy and lhellhll IloIe Is " tile tOIl. a/Igoad wIIh IhII 0UIIet nola In tr. housing 1_ illustration 1..8b). FIt tr. _ _ onto IIW housing. II'IerI InltallIhe bolts and lJOh'In them to thl tOtq.... Mttlng ~>I>d a\ tile beginning of thl Cheptar 1_

Uluttralion)

3

6.11b ••• and _

tr. ...........tat -

YV'IOOOA modallhown

6.10 ThwmoIUlI,"Iing_-up

3-6 Cooling system

tha rwIator 1_ s.ctIon ')' 7 ChecI<. tha IIdiIIlor for algol. 01 cIamagI a1d clear any !kI or detIriI; that might obWuct ... flow and inhibit cooling If !he nId.. tor rona _

Radiator removal and iostallalton

badly damaged or broken the radlalor mull be renewed. Alto check !he rubber mounting 1I'0""""tl, ar>d ~ them with ..w onM H

Remove /

&. 1 •

Warning: The .,.gl" e mul! be comple tely coe>J befOB ca",i"l1 OIIt fills prOt:«Jvre. tloI fairing ~

~".

pan'" (_

cn.pw III.

On 1993 and 1819<1 VZF750R and

I

SP rnodeI$, . . , rfImCM! Ihe fuella'Ik a1d . . lilter houIIng ( _ Chapter 4). 2 Oraon ~ cooing syst .... (_ Chapter 11. :I Trace the fan motor ~ and djSO<>nl*'t It et the connecto... On 1993 and 1994 YZF750R and SP ITI(lo(!M, they ere lOCMed in Ironl 01 ~ c:a1luret1ors. On III otNr II'IOdeIs. theN II on. on MICh end 01 ~ ~or l 1II.,.nt1on

4.31

• sa.d<en Ihe~MCUR'III" ~ ~ ....... and doolach 1h«n from lhe radiator. nodng wtIo;:I1 fits wheAl 1_ .....IrrioM) 5 UnlCr_ the four boIIl aecuring the ~or. not'ng the ~ 0I1he collin and rubber g'ommetl. and c.r-'ully mlnO&\lVr. the rediator aWly Irom IIIto mechInIt. notong how I ~~.

~

fill.

r"""""" the cooling I_from

......,

Insfallation

"'-

8 Inst.aIIatiDn II ttw . - of ....,.",.... OOI.-.g ~

.......... the ...,.,.. collars ItId ~

.... eomICIIy installed wIf1"I !hi

mounbng boII:s. Tlghtt/l'l !hi boJts 10 !hi ~ NtIlng ~ at

!hi ~M'ng

of rile CMpter. b) M«i
~"".

c} E"mI.nIrhI coooIInr ~ .... kl good conGftton tNe Chltpl« 1).1tId .... secvWy ~ by m.;.,.".,., ....... new~If--.y.

d)

On ~""!hI e<><*VJYltwn .. dextib«J kl C/wIpl« I.

Water pomp - check, removal, seal and beat1ng

renew-a!, and installation

~

nol sure ,bout theor cond~lon, remove the pump and checl< 1h«n vleually. IooIun
""'""*""

---,

Removal 4 o...n 1hII coo&.nt (_ Chapter II. ""- I .... table COfltalner below the waler pump 10

catch any ' . .Id.... .. the Wirer pump is ...5 Remove the Ifont tprOCket cover c_

Chept"6). I Slecken lhe cllmp Heuring Ihe coolant hoM 10 the pump cover 80d detach lhe no.. ( _ illustration) UnIC,..... the bolt $tICuring

the cooq,nt Ylullrationl.

~!»

to the en.glne (lei

Check 1 n. WIler pump itr 1Ocat~ on the r.tI.hw\d !-Ide 01 the VIsually cI>eock the I .... arOI.Wld the pump lor 19"1 01 ~.

WIg,....

2 To prev.nt HolkJoge 01 wat ... I,om the cooling .y&t.... to lhe lubricatIOn 3ysl.... IoI'od vIctI _ , two _Is are Iitted on the pump !haft. The $811 on the wat.. pump . , . is 01 tllto mechaoicII type which beoIA on the raw t_ofthe~. The~"",wl"khll

"""""'-d '**"
nom\Il IMthwtod .p IV!» II on lnIpectoon theN .... ~ of 1eM
&.8b Unscrew tha boll (...-owtod) ~ Ihe pipe

Cooling system 3- 7 7 Tn. pump c... ~ ~ complel_ by unscrewing lIMo bolts lhal INICIJfiI II 10 the

eran_H, INvIng lIMo remaining boll.

_!My'"

01 ~ boll ditIeren1l1ngtt1a. If1d _ ' - ~ ~ fi'aw the pump 110m lila CtW'lkcaM, noIirIg how ~ fils, bringing

=-co:~~= ~=~o~c!.-= "I-:~~!=t::

O·rIng on lila pump body, Separata lila pipe 110m lila pump. Ramove lila O-
dl8clord lIS O·rlng. and also not8 lIMo IWO ~ ,*- 1_ II~.

Sea' and bearingcower. renewa'

• RamcMo Iha pump therllWJ'lOYe lila pump 1_ above). • ~1ha~onlhairr(lal_1lhat'l:1f1d ~1hdrII .. the Impeller the housing 1_ Il1lKtratlon).

'rom

e.1b .•• and withdraw Iha pump from Iha cranI
3

,,-

8.' Wilier pump. inlet/outlet uniol'll and thermostat componentsthere will btl detail dltl.....c" ~...... model. 9 LoxaU
8.7d !f11Mo co....< hale been remo\'ed, dlsc.rd ita O-rint

12~washw

3-8 Cooling system

8.1~

...

FIt a ....... O.rlng onto uch _

"

01

10 To I'1IO'1ftW the t>Mr;ng, tap ~ out from the Inaide 01 the housing uelng a bearing dri_ (It suitable socket. 11 To '''''_ lhe all seal, II,st ,amov .. the bearing (see above). Tap the seal out from the In$iOIt 01 the hou5Ing using a bearing driver (It witabl .. socket, noting which way round 1hI! seal ms. Discard It as a new one must be

.,,,

12 To '''''_ the m&c:han;ca l nal. tap th" seal out from the OOIside oIlhe housing tJSIng a bea,lng driver 0< suitabl" socket, nollng _h way round the !leal fits. Discaid H lOS a . - c:ne must be litted. 13 s...-Vamaha Bond 1215, OUIck Ga3kM , (It a suitable equMdent to !he mechanical seal housng , then press (It carelUly
........

17 SlIde the drive shah and Impeller into lha housing and secu,,, H with IIIe cIn;Ilp, making ....... il Is properly seated In ils groove.

8.19b AlIgn th .. slot In the wat ... pump I-haft lan'Owedj .

Installation 18 If ,emoved, install the new cover a·rlng Into ita groove ISH lIIuttration 8.7d) . Ftt IIIe co_, making sure ~ locales onlO th" .. nl. and tighten th .. bolls 10 tile torqL>8 setling specified al the beginnng 01 the Chapter. III FII Ih .. new pump body a·rlng I. ... Ylusttation 8,lcl and pipe O-rngs and smea, !hem with grease ISH illu.tratlon). Press the pipe Into the pump. Check tha posI!ion oIlha lab on the«>d 01 the oil pump shIIh, then \urn !he waler pump shah so that its skli will a lign with the lab on installation lsee illustrations). Slid" tile pump inlo th e eranke ase, making su' .. th .. 5101 loeal... correctly ove< Ih .. lab, and simuHaneousIy IiI th
""-0

22 Refill the cooling ' )"Item I...... CIlapt... 11.

9 Coolant hoses, pipes and unions removal afld installaliot1

~

~

Removal 1 Belore ,emovlng e hose, pipe 0' union, drain tha cooIanl (see Chapter 1).

2 Use a sc,.. wdri_ 10 .Iacken Ih .. large'. bor.. """" ciamps, !hen liide them back aIoog Ih .. hose and c~a, of Ih" union spigot. The smaller·bore Maes a,,, secu,ed by sp,Ing CIampII which can be .. xpanded by SQ\IMVng their ....... logMher w ith pllet$.

Caution, n.e radi910r union. 9110 lraglJa. Oo not us .. ",..CtlSrJve force ",hftn a tt~ptlng to remov .. the hoses. 3 n a hos" prov... stubborn, ,,,lease It by ,otaling H on its union belora worldng ~ off. II a ll oHse lail. , cut the hose wilh a sharp knlf.. Ih"" s lit It al .. ach union 50 Iha\ It can be pealed oN In two pieces . Wllilsl lhls m.... ns the hose. ~ is pnoI...abIe 10 buying a

'_wing

newradialOf

4 Remove tM cOOlant p
Installation 5 Slid .. Ih" c lamp onto the hosa and then work ~ on 10 its respective union

=

"the _

ia r/iffICun lop
•

on il. union, II can be sofl.anad by .0.1<1n9 It /n val)' hal wat ..r, or ""emat/vwly • IittItI SO/JpjI ",.t... ""n ba used 9S a /ubncant

HI

II Rotal.. the hose on ~$ union 10 se"~ ~ In position belor" sliding Ih .. clamp Into ptau ~ securely. 1 II the water pipes or unions on the engm.. nave""""~, Iii new O-mos and ~ !hem with greasoI. Ihen Inslall them and tighten Ihel' mounllng boilS 10 th" torque ""'ng specified at the beglmIog 01 the Chapter . and toghten;ng

4·' Chapter 4 Fuel and exhaust systems Contents

_ChIp!_

AIr m.r '-'11-"""""" a'ld II'IIIaIIatlon • rod....wlll ......... AlrIlull1l'lixu.8djuItm.nI-~ ~ ...........••.

AIr"'*' _

~

•

EXUP system - chid< ..

1

FUll " - ____ .

~

Fuel pump.-d rWy-

c.t:lo.nnor~-QIIIlIIlIIIInIotmalIon

6 c.tM.or.nOt~ .................IMCI\apt., Carbufellors - disassembly. c:i6IIrOng and Inspection. 8 Csrblnnors-.-nbIyU1Clfuel .... chId<. . 10 cartuettor. -......,..a' and lreIa&.tion • 7 Ctorburenors - separation WId joining (YZF75OA aoo 'fZFl000 mociIII 00'II)1 cr.c.... ..... -IWTIOVIII...,;I . .~. . .•••..• 12 ~t;yIt .... -"""""'.-.dInllalla\lOn, .•.... 13 EXVP lYS,em-C8IbIe...-... check......-III WId ~ ..• \.

e

• , ..••...••.. _ ChapI_ 1 • ..... 1 ~

~

_ _ In! ~ .......... 15

F... _sw\tch-I993andl994VZf750~ ........... 17 Fueisystem-chId< .• , ..• " ..• , ... , ... Fuellri and fuel tap- removal and installation 2 Fuel t ""-~and~. 3 Fuel warring light cneck....:l JWWWIII .••...•. 16 General inIormation and ~ IdlupMd - chid< ........................... Chap!« 1 ThrortIeMd""'*-"""*'--chId<_ ...._ .....

_Chapt.,

...,;1.....,..-

ThrortIecablM-IWTIOVIIIr.d~.

Throttle ~ _ - chId<...cI

~.

o.pt.,

. ......... 11 . _~ 5

Degrees of difficulty

-.

Specifications F"~

Fuel tank ~ fondudin\j.-w) VZF750R _ SP models •.

VZFl000A -..

models

VZf750R Ifld SP models . VZFl000R models .

-....-

19.01itrtos 2O.01itrtos

3.5 ttr.. 4.5 ttr..

Carborenors

Hole: ~dItIo il'gMIrIlrxUK MId US ",."..modIo/I< - ~".,
YZF750R _ \1183 and l W4 UK onodeb

Fuel level (1M leK\,) .

_. ,.

Plot _

~

(\U'ns QUI} •

MIlinIM C)tncIwI\ _ . . . ~2_3.

~1....:1'. ~2....:13.

"'-

CyIIncIeno 1 ....:I 4 . ~2end3 .

Ne«llto.., .

PIlot_let.·

PiIoIIet ..

S,.,.jM 1 . . . .. .. .. . , •. ~jM2 .................... . ................... .

• • Mikuni BDST38 6.8 10 7.8 nvn llbo-. ""'1 o;hamboor I...... _Chap!. 1

,

'"

"" "" """" ."",. H

.,'"

57.5

"'

•

4-2 Fuel and exhaust systems

m_

Carburettors (continued) YZF750A - ,995-01'1 UK

'''' . Fuel

~

(see texl) .

kSleapeed .•

-,.

Pilot screw ...tt.ng (tLJmS out} .

Malnelrjet Cylinders 1 and 4 . Cylinclon 2 and 3 .

"'--

CyIin<:Ion 1 and 4 . Cylinders 2 and 3 .

Needlejet • Pilot_jet. PiIotjM . StarW jet 1 .

StarWjet2. VZF750A _

'''' F.... .

~

"'" '"'"

5CEX3, &CEZ1' H

",.,'"

57.5

us ~s 4. Mikuni B0ST38

(see text) .

Pilot ICfIlW setting (tumo out) 1994 rnodeIA •. 1995-on models .....•.............••...••........ • . Main jet . Main ujet Cylinders , and 4 . Cylinders 2 and 3 .

JeI..-l1e . ~ ..

je1. PiIot .... je1. Piklljet •

-.

,"

122.5

.," ,., """" 122.5

" "

Stan .... jet 1 . Stan .... jet2. VZf750SP -

6.8 to 7.B mm atxwe I'\oat chambef line

_Chapter ,

Idle~.

UK~ .

'''' . (seet..xt) . F""' .......

...

4 x Mikuni BDST38 66 to 7.8 mm above I'\oal chamber line _Chapt .... ,

Pilot screw setting (turns ouI) •

Mainje1 .

Main .... jet

4,KeiI>IoFCR039 6.3 to 7.3 mm above dot ma1< _Chapter , 2102)0

'"

-,. .

"NIce '" "

VZFl000A - UK models Type .. Fuel level (SIte text) . Idle opeed . Pilot screw 9ItI1ing (turns ouI) .

4 x MiloJnI BOSR38 4.1 10 5.' mm below line on fIoIIt ohamber &eeChapt... ,

Jet needle . Pilot B.. jet.

M"""

CyIinder.o 1 8iId 4 • CylInders 2 8iId 3 .

Main Djet Cylinders 1 and 4 . Cylinders 2 and 3 .

"'_.

NeedleJet •

PiIotelrjet. PiIotje1 . Start .... je1t. Starter jet 2 .

,

127.5

.,'" "

6DEyt-53 ,~

127.5

.,,.,'"

Fuel and exhaust systems 4-3 CarburettOf'S (continued)

--..

'fUlOOOfI_ ua..-

...""

4 " Mio.ri BDSR38 4. 1 10 5.1 rrvn btIow 11M on b I ~

F........... (Me1eXl)

Pilot ICNWIOIIto'og (tumI ouq

-"-' ,...-

.

~1..,.;I4.

127.5

~2..,.;13.

.,'"

MalrI"~

-........... ..

C)"IItIderII..,.;I4 CylInders 2 and 3 .

",.

~

6DJPI5-53

"""

122.5 17.5

Pilotte! •

S-jIotl. S-jIot2.

"'"

EXUP lyetem

s.vo _ 1IaIIc:....o.tanc. . s.vo motor ...... -.nee .

5.310 9.8 K-.nn. -., 10 IIPPfOX. 7.5 K-.nn.

--__............... Fuel pump

4.010 30 oI'In-. 0 2O"C

Torque wreoch settingl FuelhInIC rnountlnga - YZF7SOR and SP models Front ITIQ\In1lng bOlt nut Rear mounllng bOlt • F..... 1ank moun1>'>gl. - VZFl000R modeII Front rrlOUlIlng bolt nul

"m 16Nm 10Nm

""" "m

FueltIp_

."m"........

c.tuettcr IcrilII txlIIs

""'''''' "',..,.

- .........

""." "' ....

SIIIr-.- ~ bolts (YZFICXXlRI . VZF750R WId SP modeII . VZFlOOOfI modeII .

Oownpopto ~ nutI . ~ -"btl' ... boll •. EXUP valve cov. bolts EXUP puI
....... ...................- ...

Genera/lnfonnat/on The luel 8)'11..., conaills of the fuel tank wilhlnt ....., lev .. sensor. hJellap. IuaI Mer, IUoH II'Jmp . luel _ . cart>o,.. IIots and control CIIDMII. ClI1 VZF750R and SP modeII. u.. pomp I. tIooNd In-.lde IiIII tank and IIaa an integ,aI Iii' .... On YZFlOOOA models, u.. luallap 1Iaa .... integral a1ra1ner, and the fUel pump II mount..:! o'..... ,ry with an !n-W...

-

"Nm "'Nm "'Nm 10Nm 10Nm 'Nm

'Nm

The cart>u ..11.... .....t on Y2F75OA and lOOOA I'I'IOGeII . . CV typeS, whil
n.er.

-.

Many 01 the 1..... ayttern servIca ~

... conakIerad routl ... mIIlnt..".,. ~ ..... ItId lor that <MIIOfI . . included in Chapter I .

Pntc.Utlonl

.1::. .

W ..... Ittg;

Palrol (paoliMJ

II

Uf~ fI~.o laJr. _~"""-)'O
on anypwf

or.n- _

01_"'"

~

Don't....oh

fl...... '" ba.-IIfIIII """'"

....' lhe worlt ...... and don't ... cw1r In • ~,..,..,. a nalonl ,,"-I)'pa ~ .prUMtlf)'O
rln . . /I off ImmedialMy ...flh • .,., arid .... tar. 1'r7Ian)'O
or .......

...-.

•

4. 4 Fuel and exhaust systems

remOve the plate Ne_ work

~ a build ing containing a gas appl~ w~h a pilot light, or any other form 01 naked Ilame. E""ure that there are no r.aked light bulbs or any sources 01 ~ame or sparks nfWby. Do not smoke (or allow anyone elM to smoke) wtll~ in the vK:Inity 01 petrol (gasoJioe) or of componentl containing It Remembe< Ihe possible presence of vapour from th""" ""'-'"Ces aod move well cleat before smoking. a-:k all eIectricaJ equipmlllrt belonging to the house, gareoe or workshop whet. wor1< is being uooertaken (see the Safety ffrsfl section 01 this manuaQ. Rememba< that cooain electrical appl iance. such 8S drills. cuttertl etc. create sparks in tha normal course 01 operat ion and must not be usad near petrol (gasoline) or any component containing it. Again. remember the possib4e p<_nce 01 furMs before using electrical ~. Always mop up any spl~ 1",,1 and safaly

2.... DetaCh the hOse from tts union (AI and retea"" It from the Clip (B)

• and the vacuum hose •

dispose 01 the rag used. Any stored fuel that is drainad 011 during 3C11"V;clng work must be kept In saa led containers Ihat ara auitaCle lor holding petrol (gaoolina), and clearty marked U such: the conla ina" tham",va. should be kept In a &ale placo. Nota Ihal this last point applies equally 10 the luel tank If Il ls ,amoved from the maclline; also r"""""bar to keep Its liller cap cIoead at all times. Read the Safllty IifSti section 01 this manual care!uUy before starting work.

Fuel tank and fuel tap -

removal and installatiOn

1 &. .

-

..

S\:::. ~

W8mlng: Rer.r,o III. ~ulion . given In Section I ~/",. starling

2.4b Detach the fuel hose •

Fuel tank Removal - YZF750R and SP models 1 Make SUre the fuat cap '" sactJNI. RIImOV9 the rIdoor's seat (see Chapter 8).

2 Unscrew the boll and remova th" pial" II8ClJring the ....... 01 the tank (sea illustration) Slacken the nut 00 the bolt at the front. 3 Place a rag over Ih" Iront 01 the tank to protect if (sea Illustration). Raise the lank at the r88r and support ;1 using a block 01 wood lsea illustration). Caution: Do not nlise fha fh. front could confact bolf~ and be damagad befw..n the tank and ~utlon.

4 ReIeas8 thol clamp secur'lng the draln hose hose, than raIeas8 il from the clip 00 the tank 1_ Hlustratlot1). AeJe""ft lhol clamp securing lhe luel hose 10 Ih" luel lap and d"tach the hos8, being prep8led to cHtch the residual luel from the hOM and lhe lu,,1 filter w~h a rag (__ illustration). Also detBCh the vacuum hos" from the tap ISM III ....tration). DisconnoIct the !vel pump and ;"vel send", wiring corneclor 1_ ml,tSlraUon). On Califomia models. also deiacll the BlAP hose lrom its union 5 AIImOV8 the rag from the fronl 01 the tank. Unscrew Ih" Iront mounting bolt nut and withdraw the boit, then c,.",lulty lifllhe lank off the frame and ramOV8 It (s_ illustrationa) II tnsp8CI the lani< mounting /lIbbers for signs 01 damage or det«iomtion IlIId replace them 10 Hs union and detach the

wlth

2.-'<1 ••• aod disconnect the wiring OOIVWM:tor

fank too high as tha fa iring .fay - plac. a rag tha stay as _

new ones w~ry.

"--,....,,..,.,

Fuel and exhaust systems 4- 5

••. and disconneci tlMo wiring ~M

ICf"QUI MIfinps spttCfflad II rn. begOTIirlg of rn. cMpter.

Removal- VZF1000R model. 7 ~ ...... the tu.I ClIP is secure. RemcJ'4 the -.;. ".,....,. (see et.pt. 81. B SI.,k... the bolt ~ the . . . 01 Ihe tarIk, tt.. ...-..crew the nul .-.d withdraw the bolt ucuring the front 01 the unit t-

-

I i RaiN the laok al the Itoot .nd auwort " UIIng. bIocI< 01 WIXId t_ -..ntionI. Tum IhI tu.I tap 011 - M'- _.:I on the ""- 01 the link t_ U....lrIUon 2.1o.j. 10 ReIeMe the clamp sea.mg the fuel I..10 1M lual lip and d-'lCh 1M 1Io$
-- .

~liftthe

I...k 011 the " " - and _

it

1_

II)

Start rn. ~ WId ch«k that !hera II no aIgn of /wi ~ !1Ion.sflul it oIf

Fuel rap

body, " ~ ~ts. the tap ahouId boI repIecId wi!h I _ _• ' - noII*Ig '-

Removal - YZF750R and SP models 14

n..

lap

lhould

nol

be

...........! ~ 'O·ring Ot

...-.-..ty from the link 0IharwIM I

pouibil~y

"HI......... AernoviI

of damaging Ihe

the fuet_ as ~ above. HI Coonecl a dr.'n 110,. 10 Ihe lull OUIIeI union on Ihl lap and insert its end In I conlal ..... luillbil Ind lorge enough lor Iloring the fv.l . .fo.ppIy I vacuum 10 lhe 'IP ullng an 1U~1I!ary hoM connect..! to the vllCUUITI hoM union and 1110... lhe tlnk to

-.

t 7 Wthe tu.I tap "'" been leaking. UgII*>Ing 11M ........bIy lerews may help t_ lIIultrltlon) . Slack... all the sc....... I lillie Int. therI !lghten !hem - "P
loll by dosmanU""IIl the tap fOt further ~. RoImoYe the .-nbIy KfewI .-.d ~ it. noting how the comP<>f*'lI

II'. 1n.p«:1 .11 componenll lOt ..... ' Ot

.s.n.g.. " any oIltle COr'I'l\XlOIIlla . . worn Ot damaged tw{ond repair. a new tiP must boI fmed. 18 1/ no fuIoI Ma been !lowing from 1M 1aIJ. ~ II hkflV thll the,a II I spIn .. tIM, In tha

VICI,Ium 110.. or In thl diaphragm. RepllCl lhe hoM wilh I ....... ana It - . . y . Wthe dioIpIIragm .~ ......... tap III Mid. 10 RImowo 11M 1CfN"S SlCUring thllap to

"""*

1 2 Io\apIcI tIM link mounling . . - . lor 09"lIl 01 .s.n.g. ... ,..riamJon !hem....", __ W'-Y. ....,. rwp.oe

Installation - sll models 13 Inllallatooo II lIMo _ _ 01 removal. notong the 1oIIowIng: fila hoses are propetty allachfld and MCUnId Dy lheir cia""". Maq I(InI fila wimg COMeCIor 13 UIClInIIy contIICted. b} On YUIOOOR IrIOCIM, /um fila IuaIIJJp ~ ~ . .nI

()N~~fllafa'lll ~ boit&/r.Jf$

c} TIQtI,."

rn.

to rn.

:t 17 FUll lap UMmb/y .......... {1/TOwed) VZF7150R and SP moOaII

•

4- 6 Fuel and exhaust systems E~..., alt .. cI ..... ng and lIushing oIlhe fuel system . •XplOSl .... fumes cen ,ema,n and

Ignrte during rape" oIllle tanl< 2 If 1M loeilaM ~ removed !rom the brkl. rt IIJ'Ic:Ud not be pIeoCed in .., _ wI"IerI spatks

or open nan-. oouId ignot" IN ....... coming out 01 11>11 tank. Be ""f)ICOII/y careful insrde geragee wIwN I nMl.nII ga-Iype .ppIienca "Iocmed. beceuw the pilolliilhl coIAd ceUH

an e>cpioalon. 4

Air filter housing-

removal sod NlStailatlort the lank lind

~

the tap..-nbly

1_

iIIItWIotlonl. taca-d the Q.q ... I rww 00.. must ~UMd. Removel - YZF1000R models 20 Thl lap aIlould 001 ~ removed ~!rom the otIwwise u.... ~ I pouoblhly 01 dam.g"'g Ihl Q.ring or

--

I"""

21 R«noYe the lull lank .. dMctIbed 1iIxMI. 22 eon"..,1 • d-.Jn hoM 10 11M fultl 0\11111

union on Ihl lap and InMl1 ~S end In I ~onlll".r sultabll Ind I"gl enough fo. IIomg the fuel. Tum the tuellIIp 10 the 'ON· pcIIIottion end aDow !hoi tank 10 drain. W1w1 the link h.. draoned. lum 11M tap 10 11M 'OFF'

......,.

23 II INIuaI tap hal beIn leaking. 6gI"IIeo:wog 11M apemb/y Krewa on In. '.p lICe may help. Slacken In. SCrewi • Irttle first. then Ilghlen thlm ..... enly .nd a little al 1 lime 10

_ure 1M CO'O" Mats properly on the lap

body. It -.goo per.ills, the tap sI>O\Ild ~ replaced with 1 rww 00... however OOllllng Ie 101' by dlimaniling In. lip for lurther inspection. Remo ... the iIUIIW$ on 1M 1_ 01 Ihe lap 10<1 dlsasMmbla It. ool"'g haw lhe

components iii. I~ecl aU componeniS lor _ or dIrJMQe. end .-place !him wtth rww or. lIS necesNfY,If ......... If.-.y of 11>11 ~omponenl' are worn or doImlllged ~ replIir and ... not IVllIIabie indMdudy. a rww tap must ~ filled. 24 R"mOVI lhe KraWI """u.lng 11>11 lap 10 11>11 taM and wI1hdrl1w the tap as-..bIy , _ lllustratlon). Orec¥d the Q-mg .. I rww one ~

. ...,

25 Clean the II'IUlI ."..... 10 'amo...... ~ of dift and luel MdilTlenl CMck 11>11 gaUZI for 1\oIeI. 11 any are lOUnd •• rww tap

should be litted .. I"" IIr.1ner is not av.llable lndIviduart)'

In.taliation - all modela 28 Installabon II the r.-sa of .......,... :cr Use. rww Q.mg on the tap, and 19'1" IN KfIIW1I 10 11M ICII'Cp.M setting ~ It! the begIMng 01 !he ChapI... 28 inIIaR the lUll tank 1_ ~.

3

Fueitank-

cleaning and repair 4.2 DetIcI> the cnn.kceM IIrNtIwr !AI ....t 11M
hoM

..........

I .... repairS to the tueI tank should be- earried out by a prollllslonlll who has experience In thla criti<:al and pQlan"llly dangetou' woric .

.. :;::;

Removal I R8mova the lUll tank (see SectIOn 2) 2 ReI_ tl>ll ctemps securing lhe crankclse b<eath., hoM and drain hoM 10 11>11 eir filter I\ouamg end detach the hoeea !_ illustration) 3 Unscrww the boll sea..Ing tl>llfront of tile housing 10 IIIe I'...... ,_ fIIUlltllion) Slacken \lie clamp SCfeWS lICunng ItM! hoU5ing 10 the carb,..,ellor Intak.. on 11>11 UndetslOe 1_ Mlustratlon) .. un tile houIong up 011 the c/lrt:>l.lrellono and

II,,,

ren-oov. ~ , _ Mlustratlon)

Installation 5 lnstaIatoon Ie the _ _ 01 .....--.I Check the cond,toon of the various hoeea end !heir ~Iamps and repll~e them w'lh new ones if

""""" 5

Air/fuel mixtute adjustmenl genera!lnlormatiort

Adjustment - UK I H \he ..-.g,,,. rvnlI e>ctnome/y ,ough at Idle or cont ............ stalIa. end ~ I cartllnttor overt"IIIuI doea not C\IfI the problem. the poIot ~ probably requ.... adjustment 10 ICh_ a smooth idle and ...Iore low ~ per1ormatl1». tt Ie WOfIh nal"", It l!\iS poont that ....... you " - the sd 10 cerry 1hit out on I mulli-cyl,nd.. mach,,,. II I, bftt 10 an\ruS111Ie Ink 10 I molorcycle dealer. tIInIr

iiPq '''··f', -iiHf ~"[i WHH~ ",," lHh .·h·'h 0'",[<, [ .h~

. -,

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i~.il ~

'~Hl

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<>.

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g!~~ "$

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h~dH~

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·"~"I. ~ n la~~$. g.,

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~~~~~~2g5 ~~~ ~ ~l l!~

H'h~n[g,.•. ~ ~ pgQ _iF~~,j!~§i! ~ n.:e ~a, - : i e ~!~~a!l - ii-~ 3 ~i ~~ aiJti~i ~~[ !~ 8.3 " I'.~.~ ,iI ~, ,,21,HF~ H ~ m'H! ""O,'! •• ~ !!ti oil __ !t

!i. I'l!

ji

£:~~:t ;;:~~ u. ~,. ~ .. ~ ~~po~~ "'1'2 ~ .'"1"-' ..... [ ,., ig.l'fl~.F'=. '0" i • -', .-." H~'·'·o' .. - • llilll~;; ~_J:III ••• 5'11;11.1~ 255~~~1 ~5.. li.I~~2~~If! " I~-m~~~ 1111;11 I~I !I!~~!II:II;I!;I-I.l;!

II' !g,.ost &Rg ! :'!'I~ "·'!'r"'M ·· I',.

i

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"I~'i~;; ~ hh.!~P~I;1!;~P!~! 0'"'' Ii< o. - ,-,.,1 -I] • 'l,t· ,

HI'~ljKI"[~ •.;, .. '1 ! i_~"f""'h i jIH[n,· ! ',h , ..

l§~ 2 fHF"'H~i'Hi-.l;ni' ,« i";).!~_g, '.- '1Ii~~5 •.l . '

,,'1-/-1 ;j~~~~ "._. ~l':!l:i!ng; P'o'" ~ ~ __

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ii~!;'~ • I ~~-

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n

t

'

-"

~

4-8 Fuel and exhaust systems

-

7..41 ••. and a.t.ch the hut., .)'!It.... hoM (8fl'OWed) from Mch end 01 the idle ~ a:tjos* from "- holder .rid IMd 1\

I/1rOuI;JII to the

~

oIlhe ca1:uettOl1 1_

"lullnllIon). Q;sconnect the throttle position "".01" wiring connector (lee Illullrellon). Fold back the rubber cov .... pulling t~ v..,t

hoM union. \hfough It t~ ume time I'" lluetntionl. ~ the ..-np. seaRIg the heat ... aystem Inlet and outlet hoMe and dM.:h

thet-... I_~ .

! Deteeh

choice

<:Iblt! from the c:atKnttors (see Sectlon 121. e Detach the throttl, CIIbles from the carbureltors I.... Section 11). ~ aceeaa II; too rettrl<:ted. de\acII them Itt. t~ CIII"bI.o"ettors haYa ~ HIed ofIlha c:yIndtr head 1ntakM. 7

the

On YZF750R ...., SP modaIa, fUIy NdI. .

the low. clamp bolta on the cylinder heed Intake rubbers USIng I auitabifl AJIen key them from the front 01 the cartllnttors lsee lIIulllratlon).

ut.....,., -.,.,..

7.8b ••• detac:h the coolant hose from the thermostat housing 1..-ro..-.dJ 10 Improve It

e On VZF1000R modeII. fully slacken the upper damp boIt5 on the ~ '-I1!Itake rubbers lsee lIIulI.ltlOn) . The bol" ". angled whl<:h makas ICCesS Iwkward - lor ""sl.. aceesl to the No.• boh. <:\tItleh the cooIarlt hose /rom Its union on the thermostat housing (Me -...tnotion). II the CIIrI:>o.Qtt.... oil the inlak.. and I'«I1OVe them 1_ lIIultmion). Note: K""P

e.....

!he~""'IO~ffIJeJ~

/rom !he !bit C/WnlJer!I .m the poftIbiIity 01 the pIs/Ofl ~ beItIg damIged. Caution: Stuff <:/ean rag Into each C)'~ h ..d Inta.. aftar removing Ihe carbu"'tto,. to prevent anything from

f..mg ... to Place a ___ oon_ below the b l chambers. then .Ieck.... the drlln ICnIw on

ea<:h cm.mber In lum Ind drain III the fuel from Ih' CIIrburettorl (see IIlu,t.,lIon) .

Togtrt.. the drV1 sa-. ~ once .. the fuel tIIII bMn drimed.

Installation 11 Inlt,lIlllon II the '........ 01 removil. noting the 1oIowIng. .. Chtdr fOI" <:lKIIs or __ In 1M C)\fndr

'"-J ...... 1UtIbIws, and /WPfKe ",.", with ' - ones " ' - Y .

0} 07 1993l1nd 1994 VZFniIJR rnodII/IIlIIId aM SP II>CIdM, If 1M ca-t:u.1tOrS . . In be ~.P<"JPII'I"",*","and /loses before /mmlling the cartllnltOfS

f-CheplwIJ.

--.

<:) "".. ...... !he c:a-bunl1tOfS _ fuII)I etIQIOed with 1M ak and ~ '"-J ..,.,.. I\.ItIOats and 1M cIiIfrp . . d} "".. sure .,/loses . . ~Ily routed and MCUffId and oot ffDppfK1 or kJnIul,d.

7.10 Certlurettor drain ac..- I VZJ'tOOOR model ahown

Fuel and exhaust systems 4- 9 e) Rarer ro Seclion II for installation of the throllifl C
r:I>ok8 cable. Ch8ck the <>pfJI1l1ion of the C8bIes and adjust them., neeeSS9IY (see Chapter I). f) Ch8ck idIfJ r;pMd and Clllbtirettor synctvonJsalion IIf!d ecJius!., """""S&')' ( _ Chapter I). Q) Ort 'l'ZF1000R modeI:s. do not forr/8t ro refill cooling system (see Chapter I).

tn.

Carburettors disassembly, cleaning and illSpecUon

At. ill.

-.

Warning' Rtf,.,. to the PNCiWtlons given In s.ctlon 1 ber.,... s tMfl1ljJ

Disassembly 1 Remove tIMo carburettora from the machine

"" described in tM

~""k>us

Stocllon. Nole :

Do not separate lhe catburellOtS unless 8:b$oIu18ly ~; MCh ClllbtintllOO' esn be dism/NllI«J wlficienlly for IJII f>Of1NI cIeIIIlIng arod Idjustrrnmts willie In pl8:Cfl on lhe

mounling bmckets. DismtJn'IfI the Clllbtirett
YZF75Of:1 models ond remoye the lop coyer retaining screws and remoye tM cov'" lsee Illus trations l· 2 Unscrew

3 Re
the piston -

/he jet needle may well come ~y w~h

~

as ~

fils Into" &eat in Ille bottom 01 the spring (_

IlIus lratlon). Carefu lly ~ the diaphragm away Irom its ..... Iing groove In the carburartor and withdraw the d~m and .-$\0<'1 assembly 1M" 11Iustr.tlonl . RemoYe tIMo ai, passage O-ring (see illus tration 10.61. 11th" Jel needle d id MI come out wilh the opting , push ~ up Irom the bottom 01 the plslO<'l and withdraw !t from the lop. II the E-cllp and space.- are removed lrom the needle, oote which notch tIMo dip is fitted into. Caullon, Do not use a SNIP Inst"""..,t to dr. plac. til. dl"phr"9m .. It Is ""sfly

""""".

4 Remoye the screws securing the Iloal chambar to the base of the carburertor and ramove Ihe ftoat chambar. noting how it fits

6.2e Carb.....nor ....mbty component. - VZF750R modals Fue/filtw Fue/T-plece

Needle....., _ I NaedIe....., O-ring

B FIoar

7

J91~

8 Stwterjer 9 MBin;et

IOPilo t jel " PiJoIBirjet 12 Main airjet 13 PiJol screw 14 Choke/Jnl
vnion 17 FIoar r:J>MnbtIr """ union

IBChokeiolnl

19 Clip 20 J91 ~8SSembiy 21 Throttle sJideI~

22_;er 23Gu1d6 24Spr/f1f1

25Topcove.-

4

4- 10 Fuel and exhaust systems

-_IDI

8.S. UnloCf_ the boll W _

1_ ~""'~. ReIrI!I¥I rt..

~ gaskeI

and discard It as a Mw on_ muSI be uMd . Nol. how Ih. Idl. 'PMold .. I, ~on"'-Ieft-I\Ind~. Using , pair 01 thIn·t'\OH ~. Glnllully

a

W'ithdraw rt.. b I pi'IOI pin 1_ 8tu.ftatlon). If - . . y . clll"llMly dItpIace "'- pin using, small punch Of • MIlL Remo .... lhe fIoal .-nbIy. noIIng how ~ Me 1_ Wlustmlon). Unhook rt.. ~ ..... from rt.. tab on "'l10001. noIing how 1111 I_ Iliultr,tIon 10.4b1. Rownova lhe r-.:!Ia va"'"

_\ 1_ m.,.tratlon). o.card Ita O-mg • a . - ona must be . - I 8 ~ It.I Jat'- from It.I holder W~. rIOt ing which frll wh .... I_ IlIuatr.tionl .

\Jnso::<ew "'- bolt ~ "'- jet holder alii ramo ... lhe ""II... Uft lhe holder up off lhe ..-III jat. OOling its O-rIng 1_ Illuatr"MIonI. 1 The pIoI _ un be rernov.d from the CIItluratlor. bill notl that its letting wi be Oislurbld 1_ H..,.,.. Hln". UJ\ICI'eW I<"Id ramo ... m. pilot lI(:"w.kIng with It, Ipring. washlr and O-ring 1_ IIluI I.llion 8.Sa) . DiKa'd!hl O-rtng • a ' - ona must be used.

........... the ........ (81....r. (c1.....

fully "".traw It. 0" Insl,lIallo". the ..:raw II aItr¥JI)o bM;ItltJ out ~ number 01 fumI)'OUw fItOf'Wd.

a RaIeaM..,.;I push 0UIm. ~ HC:U1ng "'chole.

Iln~ag.

Ih"'~.

bar \0 lhe carbur.UOf1I I. . . uti otIm. bar. noIlng how ~ Iita

1_ lluatrItIon). Jw... It.I ~

pU'>gar

r.la!n1r clips. and w\1hdraw lf1e

pI~

a~

from "'- Cllburaltor bo<:ty.

I On 11HI5-on European modall •• thrallia poaition ..-.or II rnoumed on !hi outsidrt at !hi nght-ltlnd~. 00 ool_m. HnSa' from !hi c;:arb.nnor unIIsI " II kI'lown 10 be laulty and is baing rapIaoad wIIh a new

Fuel and exhaust systems 4-1 ' on... " .. f... to Ctlapl... 5 for ctl!K;~ and adjllSlITIenl 01 !he SMSOI".

YZF750SP models 10 Unscrew and remove tile top cov ... ,etaining screws and ,,,,"ove tile cover (.... lIIustnotlon). 1 t Car9fuIIy release !he throttle ~idelrom the ttlrOllle lev .... noting tlow ttle rolle' s on tile lever anns locate In !he slits In tile slide. tt may be 1'ItoCess8fy to &lackero tile synchror1isatioo

plunger nut. using a pai, 01 thin nosed pliers W access 1$ too ,estriclad for " sp.nn ..... and withd,aw 11>, plunger assembly f,om the

carburettorbody.

22 A throttle

sensor I, mounted on !he outside of the right-hand carburettor. 00 not ,emove the .ensor f,om the carbu",ttor unless ~ I. known to be fauHy and Is being ,eplacad with " . - one. _ to Chapt ... 5 lor check and adjv$Iment of the ser>sor pos~ioo

VZF1000fl models 23 Unscrew and remov .. t he r&lalrOng $C'ew!! and .......,.,v.. the Illustrationtl). :M Remove the spring from _ illustration) . Care f utl~

t op cOve,

cover 1_

I...

the piston peel the

diaphragm aWrlf from its sealing groove In the carborehor and withdraw the diIphragm and

pislon a.""",bIy

I. ..

illustration) Using a

k>cknut and back-off th .. sc,.. w to provide some clearance for the ....... - N tllia is done. not.. exactl)' how many turns you bacI the poslj;oo 01 its screw should not be altered. How..- ~ k 18 not possibl .. to , ..move ttle slid .. withoul &lackenOng It, note its currenl posillon willi. tZ R..mov. Ih.. /fI1 needl .. hotder and wlthd'aw th. neadle from the 51 1e1&. II the E·c14p Is removad!rom tile n&edle. note wNch notch It is liltad ;"to. 13 Ramove lhe sc,.. ws ""uring th& acceter.tor pump cov .... and '","OV8 th .. cover. spring, diaphragm and O-rings. t4 Remove the screws secu~ng Ihe floal chamber 10 th& basa of ttla carWr<or and r&mOv& the IIoat chamber. noting how It fits. Remove the rubber lI"Sket and discard It .... a . - one ffOISt boo used. t ~ Using. PIli!" of thin·"""",, pliers, carefllll)' withd,aw th .. lIoal pivot !)In . II """esSSf)'. carelutl)' displace !he ptn using a smaU p
ex a fIlIli. Remove 1M noal assembly, noting

how tt fit!.. UnhooIc the n&edla

~_ from the tab on the 1Ioat. noting how II fits. Remove the screw S!K;u~ng th& needl& valva saat and draw out the seat. Discard ~. O-ring as a MW

one must be used. 18 l./n!ICreWandrlfTlO\ltltllemainjet. 17 Unscrew and rernovtI tile pilot jet. 18 Unscrew and rernovtI tile jet. HI Unscrew and rernovtI tile needle jet 20 The pilot ICftIw can be fEIfl'"oO';ed from tile carb<J,..t tor. but nol .. that Its ""Uing will be

,tart...

dislu,b8d ( s . . H. ynu Hint) . Un$C,aw and 'emove tile ptlot screw along w>th tts spring. washer and O·nng. Discard tha O-ring as a

. - one must be used.

21 Unhook th .. cho~ .. IIn~ ba, retum spring. noting how tt fits. Remova tile screws lleCuring the Chok .. link~e ba, 10 th ..

carburettors, noting the out ... ~ wasI"oeB. LifI ot1 tile bar. noting how It fits and remove the Inner pll$t~ washers. Unscrew the choke

8.10 carbwettor a....mbi)l componentl YZF750SP models ,~­

"'-

ThtoWe sJAAI .. TIIrorIJIJ lever 5 AcceHlnlrorpump

.......

._-

''''''',

12 Pilctjef 13 Needle iet

9 NefK1t. II........ _t IOMain;et

15 ChoI<e pIr.Jnger

" , .,

II

St_iet

I" PiJot~

16 ~ linkage bar '7 TIIroWe posJIioo SMSor

4e12 Fuel and exhaust systems

..... ~ of Itl,n-nosed pliers. ca<efuIIy wllhd .. w !he itt nooc:IIo hoIOtr!rom Inside the pIsIon - ~

Is a prtlSI fit, lleld by an a·rlng II.. (IIul1raUonj, Note thl spring fillad Into !hI bottom 01 !he 1'I0I0:*. fWh the jat ~ up from the bottom 01 the pilton ..-.:I ~ II from till top, noting IhI wuIw' on IhI top 01 IhI needle 1_ I~j. IIIhI E-eNp_ .~ ..... re
8~

c.t.ur.tt0l' ......bIy component. _ Y2Fl000R"-'

I Top CO'oW

2 Sprlng 3 Jet t-*1IoIdeT 4 Sp.wIg

5 .... ,,--..-nOIy

6 Throttle sJideldiapIngm

7

Floar...w._,

" Float rNve 9 ,..., jItt IOPllofjltt

II FbI' 12F101I~

13 ChoIoe~~ 14 1Mmle posJfiofI--..

--

""0

2fi Remo ... the .craws HCUnr>g Iha t'Iolot et.mbar to the baM 01 !he carbWl1lor and rlm(lVI the lIoat chambar, noting how II fila

1_ IIkratr.tlon). RtmoYa the rubbar gasket a'ld dilcard II as a new".....-..st be UNd. :ze ~ a pair 0I1I*1-00H pliers. CIrIIuIIy withdraw the IIoa! pivot pOol 1_ "'ll'ItIonl.

Fuel and exhaust systems 4-13

So25 Float Chamber ..,rews (arrowed)

--

8.2&11 W1tl>dntw DIe pNot pin and ""'ove

8.21 R_oWl th8 meln Jet (elTDwed) • If - . . y , care!ullydilpiBOl the pin using a small pullCh Of I 1\11,1. Remove lhe tIoIIl

8.28 •• . th8 needle )81 (arTDwed) •

(_ m...tratlon

to..24.:). Remove the ...-MCOrIog the need .. vaIwI _ t and dill... out assembly. nollng ho... ~ fits I_ IIw _ 1_ 1I...tr8tlonj . Diacard Its O-rIng W.... ""'1ion 10.24<1) ~_ . . . . . . . . . . . . . . .-_lTIUMbe...:l. from tM tlb on tM _I, noting how ~ fits 27 U.,..,.. ... and "",ove tile ...... n 181 1_

-........... »

8.28b R_oWl th8 screw (.ITD....cf) .nd pull out th8 need.. ...,.,. ...t

8.251 • .. andth8 pllDtl8llAl,andH tile pilot SCtew IB)

....,....ry

_w_

_ry to ac""'" un.. 0'_

count/ItO

,,,.

n.....-

_If.""~""'

aImpy

tums

fully

__ ""

_ad _ ""' .......... 0 # _

IJnM:tew and ....-.ave th8 . . . . jel l _

211 Un....-.w and ......av.

....tr8tIon). 30 n. pilei _

can be

!tie pilot

Jet 1_

~

from IIw

carburlttOl'. but n
disturbed I'" Hayr>ea Hint) . Unscrew and remDWI the pilot ..,....... Iiong ... ,th its spring, .... s her and O-ring (a. . Illustration SoH). DiIcIrd the O-ring M ...... one must be used.

31 Unhook DIe cI!oks IinkIge bat rIWr"I\ ~, notong how ~ fits ( _ iIIustntlon) Remcr;oe the SCfews securing "'- cI!ok. II~ bar to t ile carburett"..... noling \he _ tic: ........... ( _ Illustration) . Lift 0/1 the .,.., noting how

~

tIts (.... ~lustr8tlon IO.22b).

Un.,,,,,,, the choke pII.roge< 1"llI, lJSing • pair of thin 00IId pIIen H IICOeM is too restricted lot • IIPIMe< 1_ llluslnltlon). and withdfa... tn. plunge< ........bIy Irom the CarburlttOf body

1_ .....lnItlon 10..22aj. 32 CerIfuIiy .,...;th
8.31b

4e14 Fuel and exhaust systems

o

CIIrburettor. Als.o check that Ih. buU.-fIy is cantnll on the shalt - If lhe ICnIW!I securing ~ to the shan hav. com. loos. It m.y be Cllchillij. On YZF750SP models. check the ...... on the . . . of the !eYer anna II"Id tile slOII In lhe slides. Otharwiae. replace the

0

~wltha_one.

._-

~ Ch..:k the floa t lor da mag •. Thl. will ",s u. '1y be appareot by Ihl presance of lue l

inIida the 110111. If ~ ~ 0ImIgIId, ..,...,. ~ wiIh

8.37 Choke plunger ~ -

8..38 cn.cto;!hI t.pend portion of ItM pilot

YZFl OOOf'I modeI.mown

SCrew Ilrrowed) lo r _

33 A ~tvott~ po$ll~ sensor I. mounled on tt.. outside oIlhe rlght-lland cartIunIrtor. Do not remove the -.or tram the carburettor u....... it is known to be laulty Ind ~ being NPIaced with a new one. ReI.- to Chspt. 5 tor c:heocl< and adjustment 01 t h e _ .

31 Check the operauon of the choke ~ as....,bIy. 1/ It doe ...·1 move smooill/y, IntPICl the nHd~ on lhe end of the choke plunger. Ille &prI1Iij and lhe plunger Nnuobar t_ lluslntlon). RIpIace the..-nbly with . new ooe II en y compooeot II worn, d.m_Qed or bent - Ind ividual Pl'rtl not

Cleaning CIullo", U.I on/)' I petnJ'-"", b..eel ~1 1rN ~cJoNn.hO.

-"" ..........

OM't use

34 S~e the metal componer>t, in the Klv .... t tor ap pro.lm.tely thirty ml"vtel (or ~." the d irections ~ ~). 35 Alt. the cltburettor hal _~ed long .-.ough for the ~ 10 kx:$n II"Id douoM of the YMniIh MId 0Iher depoI/tI. I.e I "YIon-bttstied brush to r .......... the Itubborn ~lt 5. RIn5t It again, then dry It wllIl compressed air. 31!1 Use.jelot~airlObiowDUlail 01 the fuel II"Id ... pusagee In lhe meln and upJIIIf body. 00 flO! ~ 10 blow through tile ... )olea ...a ~ In the lnIIke -'de 01 the CIIrbure\tor. The leis can be removed If

""*

-"".

Clutlon, /11_ eIflj" /he iel_ or pa' uges willi ' pMce of ..... or. drill bit. I I IINy will be ."'Irged, CIIU-'ftQ u.. fuel air ....t.,;".g tal. to be .."..L

,,,d

Inspection Nole: On YZF750SP models. llId/vidu.' cwburelt(!( bodIa ... 1101 • .".JebJI _ If th.8 J. • problem willi one of ,lie bodIe., /I I. ~ 10 ........ all four tIodIoN sa I set ~~-~~.

.re

aval,...

8...... cn.cto;!hI Yllve'e spring ~ rod Wind lip (8) lor w"r or damage

~

VZFHX)OR models only)

A

Warning: R.,., 10 the ptWCIUtlorJ.

I

",.,..,

-

proc;ftdjrIg.

/to

$Ktion

I

befo.-.

Caution: Do not """""e the Clltl>ureltor"l 0<1

YZFniIOSP modal..

S.psration

38 "...-nov.:! from the ~. c:hIdo. the tapenod portion of Ih . pilot SCteW II"Id the spring and O-ring for wear or damllge ( _ ''' .... t .. tlo,,) . R.~ the 1I!I!I","b/y with.

I Tha carburenora do not nHd 10 be NJ*Iled for normal ~ " you ANd 10 .".ale tn.n (to repI..:e • carburellor body whh • nlW onI. lor e ~ am p l el, ret ... to th.

new one If necessary - Individual pertI .... not available.

following $lfOCed ...... 2 ~ the carbl.nliorl from the ~ 1_ Section 7). Man< IhI body 01 INCh ~ wiIh lis cyIIndar kQIllon 10 ...... that It Is positioned oorrectty 0<1 ~ 1_ .luatrllion 8..21 or 8 .2311 .

30 Check the Clirbut"etto< body. flOIII Clllmbar and lop COYet for cracks. distorted IHlIIIij aurfac:fl and 01'-
the

3 Make. note of how the ~ hrolt ~ raturn springs, linkage ......,bly and c.rt;>uraUor 10 .ynchronlsatlon &pring' sr. ....... ra thai they _ filiki corr.ctJy on .--nbIy 1_ i .....tratIonal. Abo IIOta tile arran.g.amant of Itt. viriold hoses, unlonl, )oInt pi..:•••n(! cojl"l, and of the c.bI. Drackal. l _ iIIus trltlon.). • On YZF7~ modeII. rwIMse and push out IhI cIIpe ..curing tile t:I"IoU linkage D.r 10 tile

~ pomp dlaf>hragm lor splits. holM and ganaraI Oet.-.ono!ion. Hokfillij h ... p 10 a

CIIrbure!tofs 1 _ lIustnItIon 8..8aI. lift 011 tile t.". noting how it fits 1_ ....trIIion 1l.8bI.

Ilghl will help to ...,ul problemt of this IIIIt ...... AJso dlec:k the IIptIng for distortion. .~ Inseo:1 the piston or alO:Ie In IhI C¥burettor body and check thalli moves up·lnd·down ..-.oothIy. Check Iha au1_ ot the piston Of Ibde for wear. 11 If I worn eXQMli~ or doean·t ~ lmOOIhIy In IhI gIQ, ,..p.:. the comp
5 On YZF t OOOR ~, unhool< Ihe chokl IIn k.~ bar retum spring, IIOMg how II iii' ( _ il lustration 8.31.). R¥roove the ICIIWI sac:urlng the choke I!n ~ lge bar 10 lhe

..,t'"

40

On V2F150R lind VZF101Xlf\ modell,

check .... piston diaptvagm for splits, _ and gen«aI deI.nontl lon. HoIcIIIIij h up to •

light will he lp 10 rev"' proble m. of this ~~.

.t

On YZf75O$P

modell,

check

If thalip Is worn.

B

Ii C8rburetton - separation and ~ joitllng (YZF75OA and it..

.. Check the lip 01 ~ IIoet rIMdIa vaMo and the valve seat It -' Iher has grooves 0< scratches In h. 0< II In any wa y worn, IhlY must be renewed as • 8111 1_ IlIul1rltionl. of! Oparat. the thrott le 111111 10 milk. SUr' tile throtde btItI.-IIy (R modIIotI or lever (SP modIIotI 0I*II1"d cIosea....oolNy. 1/ h cIoePl'l, clean the I hrott~ linkage. II"Id atao Check the butt..-tty for distortion. or for any debrl. CIIught betw"" Its ella- and Ih.

VI""

.,...anged

twbureItors. noting the piaIIIc wIIhIrI 1_ lluatrllion 8.31bl. Uft 0II1ha ta, nQIong how ~ fits 1_ liuatnotion 10-22b). II The ~rburetlora .... Joined by two IoIIij

boll. which Pl'11 through th"," [I. . lIIustrltlonl) . Remove the boks and Iny spacing collars. on YZF750R rnodeb noling how tile c;:hoka ~ !eYer fils on the lOp boll. 1 Mark the position of MCh carIlumtor II"Id geoIIy ~te them, nQIong how the \IYottIa InkIge Is coonectkl. and baIrIg CIIrill not to lola Iny opri"9" Of lull aI\d ...,t fillIngs ItIIIt .... pr..u betweM the CIrb.nIIora. notirlg Ir'1 o-ringlliItad wiIh \hem..

Join/nil ~ filled. Inslall new Q-ringI on tile lull and villi fittings. LubriCllte lhe O-rings w~h •

8

Fuel and exhaust systems 4 -1 5

9.3<: Carbuntttor aasemb/vYZF75QR

m~lt

9.3d carburenor aSMmbtyVZF1000ft mode-It

4

9.611 carburetlor loinlng bolts (arrowecQVZ1'75OR mode-Is

USb CsrtMJrettor ioinlne bolts (...-owed) YZF1000ft model.

4- 16 Fuel and exhaust systems lurn'ng lhe adjUlhng 0<; _ _ • on the tIvol1le linkagl, H necessary, to IqUlhse Ihi clearancl between Ihi bul1e
10.11 Make MnIhe-'otInNCtl"'"" IocatH cornctIy bothInd Ihe nipple on the tond of __ choQ pIungM' (.....wed)

1001b SK.... Ihe ...... wlththecllpe, maklng .... they locate comocttv

IghII\Im of 01 &'Id Instal 11M fit\lngs inlO tt.It r"I>KIo.... 1'>oItoI. mlklng au.. they _ I

II On"YZF1~ models, lillhe choI<.e ~ t . 0010 the pIurI(Ien , _ illustration a.ab),

c;ornp.ttoly c_ IA...ua1ion 8.210 or 8.2:s.)

making """ 11M IIotllocata 00I'I"ICI1y ~ the nIppIa on the end of each chok, plungw I _ Illustrilion to , tl) . SecUr1l IhI hnkage t . In place with the c;hpa, rnamg ..... \hair ends locate OWl( \he enda of g<.cIe

II PoslHon lhe coli IPfingS between Ih. ctrbu..l1ors. g.nlly PItM Ihl carburlllorl lOQe1hIr,!hen """I ...... 11M throttIIo ~ _ correctly engaged 1_ IUullrlltlon 8.3a

or III. Qw:k Ihe full &'Id -.II Iitbngs 10 make . . . 1Iley WlQII;/II propeIty .... 10 Install Ihe two long ItIrough-boIIs w,lh their coIlal'$, on VZF750R modll. not torgett-.g the Chokl cable lev. wilh Ille t~ boil, bul do not YII tighten them. Set th. carburlllors on a II1MI 01 glass, thin Ilign Ihem with s 'Ualghl_~ pi""""" along lhe Idgee 01 \he botee. wt.. the cent ....... 01 the cart>wet\ors ..e -.II In horizonlal and wtftICII alignmenl, l.ghlen \he ~ \0 thl lorque HIIing I91CH-.3 II \he ~Inning ot \he Chapl ....

!he"

(_lIustr.don ID.fb) 12 On VZFlOOOR ~, iii thl Chok' -.goo t . onto Iht pklngIrs, making .... Iht aIoIs locate C
Ilklslrlltion 10.11). FltllM plastlC ........ ..-.d ~nkag. bar In pile. wllh Ihl 1_ lIIu._11on 8.3lb) M........... the chokto I.mOOlhly and rwturT-. quockfy uncW tping ~. 13 Instal the \tVo!IIe ~ion apr\ngI ( _ IIIUlI..II.,., 8.31 or b). V.1 ... lly Iynchronlse Iht IhrOI1I. ool1enly vllves, secure lhe

ICI"IIWS

lin'" 01*""

10 CarbtJrlttorsreassembly and fuel level check W~Re"'fOtIII~

g"'''' A. .....1

in

Sactlon

I

beto ...

NoII:Vf7>Irl~Ihe~ba

!he til ... 0-11nps, MIh V
SUA! to IIU'

rhey-.....,.~.

Reassembly VZF150R model. 1 AI Ihi Cholcl pI"ng.. ua«nbly Into \he c:arbIftIIor bOdy. maIdng ...... the cIl~ ~te oorroc1ly In their holes. FI1 !he choke linkaQI boll" onto IhI pIlIngers I - Wlutltnltlon 8.8b1, making .... Iht IIIoIs IocaII COf"I'IC\Iy ~ Iht nipple on Iht lind of ~ choI<.e pbIger 1_ llh.. tratlonj $ec\n the IinQgi to.< in piece W'IIh \he cIipe, makong aurl IhIIir ends locat. ()YIO" Ihi ..... 01 lhe .ckle 11'- 1_ illustratlon). In",,11 Ih' pilot screw 01 removed) along w,th 1tI apnng, WISher and O-ring, turning ~ in until It _I, lightly 1_ III".trlllon 8.e..). Now. IuTIIht _ ouIthI number 01 ,....

:z

~ ..corded, or .. ~Ied ,,' the begi'w'Ong oIlht ChIIpter 3 et.;Io Iht <;Ondinon of the jet hoIcIw O-ring aod use • new one If II I, d"m"ped Or delerlorlled 1_ Illu"lrltlonj FII the O-r'ng Inlo Ih' lINe 01 the hold .. , th.., Inll,,11 the holder 1_ Inull'"lon), Fit INo coil ... end tight.., lhe bon ( _ In",tratlon,), H removed. Installht jIMs In Iht jet hoIcIw 1_

iIIustralion8.e..j "' F~ • ' - (king onlO the ..-III VIIve - . IhIn p". .1 II InlO place 1_ 1I1",t.. tlonj.

10.3a Make an the C).rlng" cornctIy located In the to... of \he Jet holder , , •

IO.3c ••• and fit the coIIr ...

1O.3d .,. and IN bolt ...

ID.3a _.. _1lghIen the bolt

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4-18 Fuel and exhaust systems Now. tum t h e _ out the number 01 lUI'.-. pr..-lously r_d«!. or as !IpK~11Id .1 Ih_ beginrW'og 01 n.. Chapter. 24 If removltd, fit • new D-rlng onto Ihe nMdle vahoI 18&t. I ' - press ~ l1'li0 piece and secure It with the 8CfIIW Is" 1II .... I•• tlon.j. HooI< tl>e no.l ....... v.tve onto the tal:! on the no.l asaembty. lhen posIIioII the IIoIot .-nbIy'" the cerbutenor, maIdng .... the ..--.. ....,. Iocat.. in the seat. er>d Instsllthe pin. making lOr. It 15 -.cure ( _ Mltntnmonsl. 215 Ins~1 the piot let 1_ Hlu.tr.tlon) . to.22I> . .. end Install the linkagot bar, making _ _ 11M Mb In 11M arms IocN bst*>d the nIppMe; on _ piunge<s Z3 Instan the pilot acr_ CIf .-moved) along Its spring. washer end O-ring. turning ~ in unlll It seats lightly (... IIIUI"etion 8.29).

with

10.2411 FIt IhII velvtl _ I uaIng. new o.rlng ...

205 Insta/llhlo

'-* let 1_ lII....trlltIon).

27 Install the main 1M (aM IIklstrlltlon).

28 Ale __ gaQt onto IhII b t c;hsmber, making .... ~ II - . d Pf'OI)8I"Iy in Its groove.

then In$tall the ch.mber on the urbur.1tor tight.., its ICrews -.cutely I'" m....tratlonl.

and

2Il If ~ lit the SP8I* WId E-clip onto 1hII ....... maklng ...... theclpil ... lhIo ...... grt:I(M!I from which ~ was removIId.1'-1it the wash .. on top ollhto clip (... 1II.... t •• llonl. Check thai the ~ and O-ting . . fitted to the ....,It hOlder - UMI • new Q·nng If necessaty. FlI the jet needle into ttMt piston, ItWl fifths . - - . eniD ft Ifld press ~ gently down until it loa HCWe 1_ lIIu.l..llonl). Fit thto plitonldlephrllllm sssernbIy Into the catburettor and lightly push the pliion down, making l ure the needle 15 correctly ellgned with the needle jet llfll 11 .....1re1Ion). " ' - the diaphrsgm outer edge into III grOO'iS. milking sure it Is COITectly seated with the tab on ttMt ~ ioca&Ig COI'I'ectly Inlo the recess In thto cart;u'ettor. Check the cfII,ptngm loa noI CtNMd. SlId that the piston mo ..... s.moolhly up and down In !tie guide.

"'**

to.24<: Kook the ......... v...... onto the tab on ttMt float ..•

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4- 20 Fuel and exhaust systems

IIuIntionl. SlIp the cable out 01 the Drao:;qt lind delach the nipple from the catblnttOtS

11 Throtts. e8bIes removal and Installation

& , •

WM7IIfntI: R_,., to the ~/onI' p.n /" PfOCftding.

SKtloll

1

"tor.

Remo"al

11 .411 Pun the boot bacII off the housing ...

1 R....av_ th_ 10.1 tank and the air lilter houIIng ( _ Secticll'w 2 and 4). 2 Mart< .acn e.bIe ItOOOfdIog to ~. location at both ends. 1/ new cables are being fitted. mmc/l tt-..m to the old cables to ........ ~ ... corNCtI)I1nst8lled. 3 SIaeQn the .......or (opening) cabI. top nuI.oo IIn.IIt up the elbow. ~ dde the cabI. down In the bracMt I.O'IIi the bottom nul III ..... of the .....rl lug on !he brack ... t_

1_ 1II... ltallona). Slacken the ~atOf ~ cabI. - . _ ...,. the cable down In the brad
-.

lind delach the nipple from the carbo.IrenOtS t_ Illultratlon). Wrthdraw the ClIbIa. /rom the ....chIne no\II>g the correct routing of MCh

4 Pull the robber boot back off the thlottl,

housing on tile handlebar (see IIlultratlon). Ramo~a t .... throttle housing ICrew. and MPfIrltl the hat~e5 (5_ illuatratlont) ~ t.... cable elbows from tn. t.ou.Ing • noting how they lit. and detach tM cable nlpplel from the pulley 1_ lIIuatratlona). Mar1c each cable to ensurl ~ is coonectad 00I1"KtIy on instaIIIItion. •

Fuel and exhaust systems 4-21

11.4e . . . and 1.... the cable..-ds from the throttle pulley

Installation 5 lubricate the cab~ nippl.. with mu~i· P'Jrpo" lOrN" and Install them inta the throttla pu lley at tha handlabar (see Illustration 11.4e). Fit the cabIe"bows into the housing. making sure they locate corr9CtIy (... Illu stratio n 11 . ~). Join t he housinlO ~. making sure the pin IOCat. . in thtI tIoIe in the handOlbar. and tiglltoo!hol screws ( _ lIIustr&tIon. 11.4c and b ). Fit the rubber boot (_ illustration). II Feed th e cables throuoh to the carbureUOf*. making SUfe they are correctly routed. The cables must oot lnterfere wtt!l lin)' ather component and should not be i
12.211 •. . and free the out ... cable from t he

c lamp .

socket on the carburett", Ituotl.. cam (s. . llluslr'lltlon 11.31). Flt the decelerator <;abkI1nto the bracket and draw ~ up Into the bmc:keI SO that the bottom nut becOmeS captive against the small lug (. . . lllustration 11.38). Tlglrten the he~ down onto the brecket (. . . illustration 11.3d). lubr1cate the accelerator cable nipple with rruni-pupose IIf'8IIS8 and fit ~ Into the upper soci
12 Choke cable -

removal and Installatkx1

~ ~ ~

Removal 1 Remove the fuel tsnk and the air fi lte< housing (see Sectiooa 2 and 4). 01'\ YZF750A and SP models, remove 11M lalH.tmd lalring side J>BMI lsee Chapter 8).

12.2c • . end t!Ia cable nipple from

linkage bar

~

2 Slecken Iha chol<e outer cabla braCket

screw and " .... the cable from the bracket on the front oIlhe cart>oreUOI'S. then det,..,., the

Inner cable rIippIe from the choke linkage bat arm (.... illustrationS). 3 On VZF7500R and SP modell , '-"'SCrew the boll ...::uring t!Ia choke lever housing to'acI<eI and displace It {... lIIustration l. Draw the oute< cable end 110m Its socket end 1_ 11M nipple lrom the lever (_ lllus_lonsl . 4 On YZF1000R models. unscrew the two Mndlebar switch/choke te_ housing acrews and separate the two halves (sae illustrallon). lift Ihe cable elbow end lev.". ouI of the housing , noting how they fit, and detach the cable niWI. 11'0m the lave< (• • • Illustrations)

12.301 UnllCntW the bolt and displace the housing.

4

-.00

exhaust systems

11 Throttle

..... tratIonI

'*"- -

."., debo;h

removal and InslailatlOO

SlIp !he cat» cui 01 tIw braI::MC !he nipple from the ....w.ttors

1_ IIh,lIratlonlj. SlacJ<.en the dec.lerator

Wamh!g: R.,.,. to It-. ~utIon. ~Ive" In s.c:tio" , bef",.

A::.. ..-

(dosing) cable 1'1.,., ItIen alldoIlhe ...... down In the btackel ootU the bottom OIl! II clear of the small Ivg on thl br.ckat , .... lIlustrationel. SlIp the cable out 01 !hoi brackooI and detKtllhe nipple from ItM carbur8l10fl, 1_ llluatritlon) Withdraw thoI cabIM from !he "*"*'- notng the COI'I'ect ~ 01 -=tI

1 f*nova lhe fuel tlnk and the air Mel nou.ing 1_ s.ctloniI 2 and ., 2 Mark each cable aoc;ording 10 ~ O)QIItion I'

-.

both e nd •. II ne'" ctobl.. are being Iltl~. m.tch !I-.n to the old cables 10 ........... !My

separ.u the ha/V. . , . . .

Remollal

... ~ r.t.IIod.

'** ........ tn.n""'tt.

3 SI8cketI the «aIIratOl' (~ l'IUIand~Mupt"-

lOp

cat» down In !he Ind<eI untiI1he bottom nul Ia clear 01 the amaIl '-'9 on the braeI«Il 1_

4 Pull the rubbet boot bIIck off lhe thmttle

housing on the handlebar , _ 111", I,,,lon). Removi lhe throttle housing tc,.wa and 111"11...110"1 ) .

DispIaoI1he cable IIIbows from II'MI r.ou.Ing. noting how they lit, and dellCh 1"- c.bIe nlP9," Irom the pulley 1_ lIh,o, lrltlonl). Ma rk each cable 10 en.... It II connaoetld

.,.,....;tty on lm'-llatiQn.

Fuel and exhaust systems 4-21 socket en the carb~reuor throUle cam lsee Hlustralioo 11.311. Fit tile decelerale:.- cable ioto tile brackat and draw it up InIO tho bracl<e1. so it>o' tho bottom nul t>ooomoo. cai>tive "9"inst tIle.-nalliug lsee Inustratlon II.lei . T'IIhlen the he. down onto the bracket (see m....tretlon 11.3d). Lubricete the ItCC8!eretor cable nippIII with rTI\lIti.purpoee I1"&aSe and lit ~ In'o tho '""" socket on the carbure!tor II"rottIe cern (see illustration 11.3<:). Frt tho ecca.ator cable InlO the upper bracket and adi~st as describolcl in Chap'er I to obtain the COffect 11.48 ••. o.nd ".. the cable end. from the throttle pulley

Installation 5 Lubricate the cable

nipple~ wi'h multipurpose grea"" and Install them Inlo the throttle pul ley at the handlebat I... ilfultratlon 11.48). F~ the cable .. Ibows Into

the housing. rnakWlg ...... they Iocat.. correctly (see Itlustrallon It.ad). Join the housing I">BIves. making sure the pin Iocat"" io the hole io the handlebar. and tighten the ""rews 1_ Wl ....tratlon. 11.4<: and b). Frt the rubber boot (_llIuslnltlon) . 6 Feed Ihe cables thrO
amo\.01t at freepIay (see IlIustnllion 11.3b). 8 Opem:e the throttle to cn..ck ttIat it opeoa and closes freely. Tum the handlebars back

and fC>rtn to make sure the cablfl doe-sn·t cause the Slewing to bind. g Insla~ the air fi~s< housing and lhe /vel tank (see Sec!Ions a and 2) 10 Slan the engln .. anC! cneck lfIat the lelle speed d:l9s not riM as the handlebars are turned. H it does, the throttle cable '- fOUted inoc:orrectty. Correct the problem before rIdIr>g the motorcyde.

12 Choke cable removal and iostallation

~ ~

'"

Removal

tr.... the cable from the bracket on the Ironl of lhe certllnttors, then delach the ....... cable nipple from the choke IlnkeOe bar IIffll (see Hlultratlons). 3 Oro YZF750A and 51' modelS. unscrew the boll securing the cIloke lever housing bracket and displac. It I.ae Illuslrallon) . Draw t~

outer cablll ....-.:I from Hs !lOCket and Iree the nipple from the _ 1_ illustrations). a On VZnOOOR models. unac,iItW the two

tlandlebar switch/choke lever Musing """""""

and

1 Aemo.e Ih .. fuel tank and Ihe al. lil l... housing (see Sections 2 and a). On VZF750A

and SP models.

2 Slack.. n the choke outer cable br&eMt

screw and

remove the lell-hand fairing

side panel lsee Chapts< 8).

.... parate

the

two

halves

Is ....

lItustratlon). UtI the cable eObow and lever out of the housing. nollng how thOlY ~I, and C!etac~

the cablfl nipple lrom lfIe I.."". (.... lIIustratlonel·

4

4- 22 Fuel and exhaust systems

In.talfation 5 q\allthe c:abIII -'rIce!e the c.bIe ruppIIo w;!h muItI·~ ur- ....:I ~t n Into the ~. t ' - ftt the Olrter catN and ontoib ~ 1_ iIIImmlons 12.3c and b). Mcult the brackeI onto the Irame ....:IllItIten the bOIl: secunoI)Il- IlIuatration 12.3.1. 1 00 YZfl00QR ~ •. lubiWIe with multi·purpoe,a g _ and anacllit to Itoa choka ~ 1 _ ItI"'traHons 12.4<:) f'rt the ~ and ~ elbow Into 1IMo--.g

I .... m"s tration 12.4b). then lit the two """'. . 01 the r.oull"" onto the Ilandlebar. mak,ng .... the _ lit, COITectty. and the PIn 11\ Itoa front ""H Iocat.. In the hole In the front of the handIaber 1_ Illustration). Install tlla screws and tlgllten them s&Curely Ilee IIl t.lStnrtlon 12.4a1 II Lubricate tile cable nipple wltll multi. purpose 9<_ and attach II to the choke IlIlI
-=.....

'**

MIflng nng Into the llJencar pope. Fit the sierar _ Ihe do<wnpipe~. mtkonO ..... II iI pushed ~ home. AlIgn lIMo -.car mount,,,,, ~ket at tile .... and Install thl! bok. but do not yet tighten II. Tlghten the

13 Exhaust aystemremoval and installation

A , •

Warn/IIII': If the _1I';ne h •• b_n tltnnlnll' Ille e..II''',1I .yll.m ",ill be ...", 1101. AJ_ the to cool bet_ c::anp.g out eny ...or*-

'no"'"

Silencer Removal 1 On YZF750A and SP models. for ImprQved CINr.nee and 10 • .,old \ha posllbMy 01 dlmagl! •• _ tl'lll lower 'aoring (1M Chaptar 8). Slacken !hi clamp bolt HCUfIf'Ig Ihe .u...o. !iii» to tile downpopI .-nbIy Unscr_ and fIrr\OYe Ihe lllancer moutlting batt. then release the alleoc ... pipe from tile dowropiptl assambty. Remove the INling 00g from Ihe end of Ihe .,Iencer 01' down pipe usembly and dIscan:Ilt as a roew one IIlouId

"."""

2 On VZfl000R mc)deIs, unscrew lhoIllne IIfonge boIlI MCUMg the sIIancer to ,he dowmpope -ooty. notong the gl.lWll wtIIno fitted I.... IlIul1.lllon) Unser.... lhe nut on \he ~ rTIOI.IfIIing batt. therl w,thdrew the boll and remove the IlIen,*, [see illustration). Remove \he _ing ring from the «od of \he sjlerlcer or downpipe asaetnbt)r and _ _ shouICIbe'~1I_s

Installation 3 On YZF750R and SP models.

r~

the.-

clamp bollsecu.eIy. but not overtight. then tigllten the 1,1_ mount'ng batt to the torque setting apecJfied at the bet:Ionnong of

h"'-

.. On VZftOOOR modeII.. lit the __ Halong

00g irlIo Ihe -.car. F'~ \he.-..ear onlo \he down pipe ........ bly, making lure II locales correclly ~""'t \he ~1InQR. not forgetting the gua.d wllere fined. Align the Illenc .... mounting bracket at the rHr and Install the boll, but do not yet IIghlen It Tighten tile silencer ~ange bolls to the torq ... HlIlng specified at the tNog,nning of the Chlptar. trIRn 1lItIt.... tne ailencer """"'tong boll nut to \he spec,fIed torque I.... Iftultrl\lon. 13.23 and b). S RUf> tile eng'roe and check the tystem for

-

~mp'et.

system

Removal 6 Remove Ille low. fllrlng and the 'Iirtng side panels ( _ Chapter 8) 7 o.tacllthe CIIbIes from \he EXUP vaMI (see Section \.) si~ moutltong batt but do not yet ramo"e 1\ {... Illust.etlon 13.2b) Unscrew lhol bolt HCIII'ing the ... of \he downplpe auwnbly 10 the '.a,.,. 1_

8 Slack..., \he

illustnltIon)

Fuel and exhaust system s 4-23

dow~":_:~,:....::~:":-~~::::~~:::~~

t Unacrew lhe e.ghl and draw lhe flanoes

.........

of! the "veil

t_

10 Support'ng the syslem, , _ lhe ..-...:. mounting bolt, lhen det.ch lhe downplp" from the cyhnde< I>Hd and ......ow the system tsee iIIustrllllon) I I RemoYfIlhe gasket from Ndl port In the C)'Iinder lINd and discard them must be litted

as new

01*

InstalLation 12 AI I.,..... gaM! Into each 01 the c:ytIrdso 1'...:1 portt ,_ iIIustrMIon) Apply I ~ 01 to thIo ~ 10 ...... IIWn In pilei

or-

13.12 F"rt I _ g......t into eac:h port

whist ~ thIo dowropipslf~. t 3 ManosuYrs thIo -..bIy into PO'itiOn .., hI the lINd of each dowroPPS it Iocsted In ill port in Ihe cylinder held (... lIIu. tra Uon 13. tOI . l!>en Install the ,ilenee< mounlong ~t Ind the downp'ps u....,bIy rOllI, boll. but do not yet t~I'" them 1_ IIUlu.tJon. 13.2b MId 13.81 I. locIte lhe downpops nangM 01'110 the IIudI; !hen I\t the nuts Mldllght. . IIWn to the torque MlIIOg spec,fIed at the t..QonrutIQ of the Cl\.apler 1_ illus tration) . Now tighten the 0IhIr bolts 10 the spiICI/IItd 10fQue. 15 AttAch the cat-. to the exuP ....... ( _ Sectlon 14)

13.1. F"rt the fIIongH omo the studs and ....... _ with the nuts pulley cover on lhe e~hIoliS l and remcated .. 0Ih0wn 10 "OP the jll.I01ey 1""*"11 (see I I _allon) . Draw the pulley off the ..... n and detacI'o the csl)le ends /rom ~. nol'ng which lits whera 1_ Nlul trftlon). Draw the cabin OUI of lhe bracket. nolOl'lQ whictI fill """*- ,... Mlulllltlon) Note the .prjng and washer lined on lhe valve shaft and remove them IOf . .t.keaping if !'lIQUOred lHe Illustration " .11)

w_.

Cable renewal 1 Ren\c)ye; the fuel lank (... Chapter .) and the ."..... lamg 1_ Chapler 8). 2 Unscrew the bolll secunnQ the exUf>

4.24 Fuel and exhaust systems

14.4 Draw the cabIK from their hold..... lAI.nd releD .... the IH1ds from the pulle~ (B). Se1vo mountlJ>g bolts (C) 4 Free the top ends of the outer cables from their hold e~ 00 the servo housing. noting their location. and detach the cable nipples from the pulley (. . . tllustration) . Withdraw the cables from the machine noting Ihe oorrect routing of """" cable. 5 Lubrlcat. the cable nlpplltS with mUlllpurpose grease and Im;talilhem InlO the """"0 pulley (... illustration 14.4). Fit the outer cable ands Into their hold..-s. making sure thaylocale correctly. 8 FHd the cables through 10 the .xhausl. making sure Ihey are correctl y routed. The cables must not Interlere with any other compor>ent and $houId not be Idnl<ed or '-'I

"""".

7 Fit the ooter cable end. Into the bracket. then lit Ihe nlppl as into Ihe pulllt)l (SH illustration. 14.3c and b). II removed. slode the w a.her and spring onto the shaft, then locate the P<Jlley and secure It with the Ix"t, oot lorgettlng ita wDaher (see Illustrations). Check and adjust cabla freaplay (see Chapter 'I, !han Instail ltMl cover and tighten the bolts to ItMI tOl'QU8 setting specified at the begInnIog of the Chapter.

Check 8 Trace the wiring /rom the EXUP system servo motor and d iscon nect it at the connectors ,aee IlIu.tratlon). USI"ll a tullv charged 12V battery and some jumper leads. connect the positive (."e) terminal of the battery to Ihe blacklyell ow wlra terminal On Ihe servo side of the connector. and the negative (-va) terminal to the black/red wire terminal. When the battery Is connected, the servo should operata. Oisconnect the battery Immediately after the lest. ellul/on: Di_nllel Iha bIIltery Imm.-Jilltaly afta' th e fe.t to pravent poIsibIe damBge to the ......., mol",.. " If the servo now operates . yel did not boilore-hand, check lor vollage at Ihe wiring connector using a yoltmeter - connect the positive (+ye) probe of the meter to the

bIacIooIred wiretarmlnal on the loom side of the <;<>nnector, and the negative (-\Ie) terminal to the black.lyellow wire larminaJ. Battery voltage shoukl be present. ~ not, check the connector lor loose or corroded terminals. then check the fun and the battery. """ then the wiring boitween Ihe connector and the ignitIon control unit, referring to the test procedures and Wiring Dilgratn$ln Chapter 9. 10 ti the selVO does oot operate. check the static resistance t.etwe.o the wMeIbIack wire t"""lnal and the yeIIowlbloe wire tlKmlnal on the Servo side 01 the connector using an ohmmet .... Or multlmetar set to tha K-ohms scale. Compare the reading to that specilled at the beginning of the Chaptet". Disconnect the oingle wh~elred wfno bullet oonnector (_ Illuatretion 14.8). Now check the variabla resistanca belw,",n Ihe white/black wire t....mlnel and the white/red wire Iet"mlnal on thoo servo side of the connectors whiIto turning the ...... 0 pulley by hand. Compare the reading 10 that specified at the beginning of the Chapt.... If either reading is not within thoo range SPecified, replace the servo with a .....

-

11 It the operation of t he y~lve has been sticky. f&mOya It 9S described billow, then check the valve &haft. tace. cover and housing lor any corrosion or dirt which may be caooIng

Fuel and exhaust systems 4-25 the problem. Also cn.ck!he allaft collar. In wt'kh !he ........ I....... - _In !he hcusing n ..... In Ihe COVW' ClNn 01 all din w>d COITOIioo .rod check the operation 01 lhe vaIvto. It the sNltI Wldl Of coIIano ..... worn,

..p.ce Ihwn whh _

or..

Removal 12 Toeoc:..theMlVO . ...-.:wethefulltanic 1_ Cheptw 4). To ~ the villw. IlIIT1O'Ie the ~ lalrlng 1_ Chapt ... H). Before removing eIthtr the ..-.0 or Ihe vel"ll. delach

the clbln 1_ above). II only the servo II being I'WTICIWIII, k may be -=-ary to detach the ~abln I.om the valve as wel l to e'Nte enough Mook.

13 To ,«nO'Ia the _ . delach lhol cablel . . dHertbad abovto t,.,.,., uno.cr_ III """"'ling boIb" noting the . . - grornmetI .nd ooIatt 1_1IuI1rdon I ....J. 14 To _ _ the\/8lVa. dIIadIlhec«JIM.. dMo::rIbed above .nd . - the spring .nd

Check I n. IuaI pump III _ a d InaIdo! the lualtank on VZF750R n 51' ......-. _ .. mauntad on the crOll-member below lhe fuaI tank on YZFtOOOR models. The fuel pump

Ir,,,,.

rally Is COfIlainad wtttun !he rally assembly mounted on the /toni Q/ the batt...,. box below the lank .... mounting on YV'75OR and SP ......-. and on top Q/ the fullliItw. wt1ich III just beNnd tlla lUll pump, on YZF11XK!R mod&Is 1_ lUul1rlllonl ). Remcwe the IueI tank 10 ace... III components 1_ Chapt..-.), 2 The lual pump II controHed through tlla relay 10 t"-1 ij ru .... whane_ lhol >gn~1on Is lwilchad ON and the Ignition Is opwa~ .... (II

only when the ~ .. ""'*'II ov.? AlIIOon • the 9IiIIDn iii kIIad, the r.Iay wiI cut oft the IuaIIM"'P°s aIactrIcaI .uppIy 110 !hid thara III no risk 01 fuel baing sprlyad out undar In the _ _ at ., accidant). ~

~

IIlol*I be poeIibIa to ' - or IeeIthe IuaI ....,..q ""*- Ihe engine III turning - ai1hIr place ,..,.. . . dosa beside the

....... ""'*"- Iha I;:JtIb IiICI.RIg the valva

3

cov. and remove lhol cable braduol and

""...., o..w out the valva, noting how ~ ma.

_

Inst. lI.tlon 15 Ina'allilion II Ilia ....'erse of removal. Tighten tlla valva co .... boilS 10 the torC/ue Mning lpecified at thl beginning 0 1 the

Ilngartlpt.. II yoo canOl hear or leel anything, chack thIIl!he batt...,. III/uf>' charged and tha ~In;ull lu .. I, good (... Chapt.. 9). Then

-,.

II ChICk Ilia Oparltlon 01 Ilia .~"em and tha cable IfMpIay 1_ ChIpt..- 1). Instal the pulley cov.- and Ilghl.., Ihe bolts 10 tha ~I~.

pump

lUll lank or pump or feel it wtth your

ellack the p<Jmp and relay lor 100.. or

corroded connections or p!lys;cal dlmage and..ctily .. - . . . y . 4 "lIMo circuli III IIna 10 lar, switch lIMo ignition

OFF. Unplug tha ..Iay·s wlrlng connec:tor. UtoIng an ohmmller or continuity tHier, - - - ' the ~ (+111) Pf')bIt 10 the.-...ya ...stbIac:k tarmlna!, and the negative (-....) Pf')bIt to the raIay'. bIuao1lIIck terrr*>el. no.. should be no conllnu,ty. LNYing u.. mat_ connec:led. now connecl a tully charged 12 YOIt b1ttary and two insulated jumPl'" wIr ... connect the potI1Iva (+ve) terminal 01 tha bllltry to the .-.y'• .-dIbIack lerminal. wid the nagatIve (_) Ierminal 01 the betr.y

115.la Rally 1 . .....bIy (a..owed)nF750R Ind SP models 10 the ....... bIIWr.od I.......... no.. -'>ouId now be controuity. "the relay ~ dON

-

no! baNva . . dak:ribad,

~ ~

with a

_

15 II the pump still _

not wor1<. on YU'1000R modeII " - Ihe wImg !rom the p
......

Removal II '-Iak. aIn tha ignition II swttched OfF. ~ lIMo l\leltank 1_ SectIon 217 On YV'75OR and SP modeII, ........... !hI tueI lIP ( _ Section 2), then ' .......... Ilia

Kf_

securtng !hi p<Jmp assernbl)llo tlla bill 01 the taN< and _ _ the p
4- 26 Fuel and exhaust systems

I On YZFIOOOR models, 1nK:_ the wiring from the fuel pump w.d disconoecl II al the conn ... tOf t.... lIIu_traUon 15.lb). Mak" a nola Of sketch 01 which fuel 110M fIlS whe<1I as an lid to In$tanabon. Using a rag to mop up 8!"1)' spilled fuel. dIsconnac! the two luel tlosee from tha futt pump (... Illustration 15.lb). Olsplae. th, rej.y from tta mounting (_ IIIUltratlon) . Unscrew tlMo bolt securing tlMo pumpJtl~ ... at .. v. to the I"me and ramov. the pump WId Mar with It. rubbolr mounting sleeve (. . . Nhntratlon) Separata Iha pump

Iromthe ........ II To _ the raIIoy.-nbly. disconnact Iha relly wWlng conneclor and removl tlMo ratay from iI. mounting ,. . . illustration 15..e.)

Installation 10 InstaU_lIon t. • r... _ 01 11M! r"""",al procad\Jr1I. 0r1 YZF750A and SP models .... I .... w Ie/II and fil ttle pump with 11,,, arrow on the base pointing fOfWard. Toghtan the screws to tha torqua $Blllng specified at the beginning 01 the Chapillf. On YZF1000R models, maka I-\Ira Iha fuel ho ..... are COI'fllCtIy and sacuraIy flttad 10 !he pump -!he hoM ffom the In_lo .... fi~1If atla<::l'M to lhe

11.15 FueoI ...... Ml"lSOt" Kf_ (arrow«!)VZFIOOOA models

union m~ ·INlET· ; the hoM to the CIrb.nttcn .nac:n. 10 the other union t_ Illustration 15.1b). Slart tha angI .... and chacll carefully !hilt u-e ar" no leaks at the pipe connac!~.

""'_-

16 Fuel warning light check and renewal

Check 1 Tha eireuIt c:or..ts 01 the s.ISOI" mounted In !he full _ and It. -*'II light rnoumad In lIMo In$lNment panel. II tlMo system malfunc::toons <;h«:k IiQt thai the battery 'tully chIrgad and IMI the bUlb and ~ . . good (Me ChIpIar 9J. H they ... _ the

*'"

fuel and CQin it (see Section 2). 2 USIng In ohmmet er Of contlnuity tallar. Cl"IeCk fOf continuity between Ihe grMl"l and black wire terminals on the sensor Iida 01 the wiring connKlor coming from lhe I"", lank. wltll tlMo link tlMo right way up. There should be continuity. II not, repIeca the -.or with a

. - one (Me beIowj.

3 If tlla _ _ '- good. Install theluallllllk, but do not filII with the fuel. Wlltlthe IgrjlIon ON. check IOf _age al Itle wamlng IIghl bulbholdar by connectIng !he positive (+ve) probe 01 a voItmet.. 10 Iha brown (YZF1SOR tnd SP modaIa) or graar>fyaIow (YUI~ modaII) Iltrm"...1 on thll loom side 01 lhe Instrument cIuIlar wiling connectOf. and !hit nagatlvto (.... a) probe to the gr-vwtllta t.........t .1I no \/QIIagoI"~, !helau~ Ii.a In the wiring. Check an the relevant w1r\rIg and wiring connaetOfS ( _ Chaple< 9), m/etring to the WIMQ Diagrama at the end 01 Chapter 9.

Renewa' • Sea Chapl« 9 fOf renewal of the warning light bulb.

5 To r.-- lIMo sensor on VZF7SOR and SP rnoo.ts, .-.movtI !he lutt pump , _ Section IS) - !he pump and -..or coma .. an.....-nb/y and must be r~ as auc~. Follow the lnltallatkln procedure . . deoIctIbad In Ihtd SactIon. 15 To 1"fInIIW!he""""", on YZFIQOOR modell, remove lhe fuel tank {see Section 21 and drain II. Free tha wifing from III clip on the tank Remove !hoi scnrws securing !hit ....or and d .. w It out of tha lank ( __ IlIult"lttlon) D*:ard II"Ie o-mg. F"n a ' - Q..mg onto the - . - and if'lti8D II ir'Ilhe taflk. TlOIItatl the ecteWI 10 the lorque $f!ItIng apacifiad It tha bagImIr>g of Iha ChIpt .... 1 "'*t&I the IItnk ( _ Sacbon 2). and cNdr. ~ thItt ",.. .... no IIIab baIora usng

......

11 Fuel r~ switch 1993 and 1994 YZF150 models 1 TIMo luat reserve SWllch is H I In thlt IIIft-

I\aod faIring slda pa""'. In normal YI8 the switch should be In the ON position, and IIhouId oN! be mIN8d to RES wI*1 Iha fuel

.... wamong light ..........,... Indic-.mg IhIII ",.. lit just 3.5 itras 01 fuel ---*'G In Iha ,..... The IIwIId"I ithouId be moved t.cI< 10 ON .flar~.

2 II Ilia fua/ supply fails to 5wit(:h over to r _ . ...far to the wiring dlll\lrlt"\1 and cNdr. lIMo _ cIrcoit wO
5"

Chapter 5 Ignition system

--.

Contents

ignition (rMin) switch - d'Mck. removal .-.:I

inIIaIabon ........................... . - 0..- " ignition eonIrOI unit - cIw;:k. ........... and ~ 5 ignition HT 00II- dleck, removal _ instaIatian . 3 ignition ..,.._ - dw;k . 2

Ignition liming - genenoIln/Qrm&tion _ elwell . S rMulrIII $WIIdl - ct.cI< n ..-aI _.. _ Chapter " Pick-up coli - dw;k 8I'Id - ' " • &desund switch - check _ _ _ .••...•...••. __ ChIpW" $pM< pLogoJ- gllpdlec:k.-.:l _ _ . . ..•.. _Chapter 1 TlvottIe position ......of - chid<. ~ and..-al . 7

Degrees of difficulty

Specifications

--

General Information

"'"*... Ignition timing

~

VZF15OR~

,_

YZf750SP modM . YZFIIXlOR rnocIM .

10" BTDC 0 1200 rpm S" BTDC 0 1200 rpm S' BTOC 0 1100 rpm

Pick-up coil Reeistanc • •

13510165 ohms 0 2O"C

Ignition HT coils P'rIrnarywindlng--YZf750R and SP modioli .

1.BI02.2~.2O"C

YZFlOOOR rnocIM •

1.9to2.501'w'na02O"C

~ winding

..--.c. (Wfthout plug ClIP!

YZf750R IIIId sP modIII . YZFl000R modM . 5p.t. plug cap ~ . Mntun ~ gap t_ s.ctior1 2) •....•••..••.... •• •

9.610 \ . .. K-ctrna. 2O"C 12 10 18 K-'*"-. 2O"C 10 K-<Jhms 0 2O"C .~

Throttle position sensor Maxlmt.m .... _ 1995-on YZf75OR....:I .. SP models YZFl000RITIQdM . range 1995
5.0 ~ 1.5 K-olma 5.0., 1.0 K-oI'Irna

A.II l~

YZfl000R~

.

T.o rque wrench se\ling PicI<-\4IcoiI_clMlp~ •..

Zero to 5.0 -" 1.5 K-<>hma Zem to 5.0 '" 1.0 K-ohmI

5

5- 2 Ignition system

u...

Note IhoIt II no ~ for IdjI.-ting \tie 19n1lion IIrT*Ig on ~ InOCI*.

1 Genefallnformation

All modal. ara flUid with a fulty trln.lt!orIMd al..::tronl" Ign~ion syslem. which dua to H. lick 01 mechanlCOlI part. ~ 101lity malnlananao IrH. Tha s~t.....

comprilet • 1r\gQ&r. plck·up coil. ignition control unit .00 9"oItIon Kl cob jMff!r 10 Itw wIrlng d~ " Itw &rod 01 ChIpt. e lot d&I'Ils). All mocIehi .... fitted wiU'I two HT c:oiII. A Ihrottle poIItoon ..-..or proYIdM InlormttiOn lor Itw Ignffion controI"";l (nol filled on lM3.-.d 1994 Y2f75OR rrI
opIf"" 11'4 plck·up coil .. the " ..nksNIfl IOtItM. Tht picI<.up coil serds. to hi ~

IgII'Iklon conlrol ",,11 which then suppliM. IN

19n1lion HT colli wIttIltw ~.-..eeuary 10 procIuctIl fI*Ic .11tw 1Ifu9s.

Wl rnlne: Tlla e ne"OY lev.l. I.. ar.cll'Orl/c lyll""'l u .. be .,..,. • hlQh. On .. 0 Iccounl u.ould III. ~ b e " - o n _'IhIp/up 01" J>Iuv c.". _ IMi-Ig ItMJ. SIIocks from ''''' HT dreull un be ...... , u..,.se..... t s - d I y. /I '- II/ItJ filii lhe ""';.,. " nol lum«i 0 ..... .,... nm wltll Iny 0' Ih. pIIIfI U p' ........ ....,. Ind Ihll til. pllIfIl a .. .aundly Nt1.h.a fQroun~ wll." tIIa cllactacl IpIrldng. 11Ia Ignillon . y l llm com""",..." Can be . .rfo~/)' dlm~acI If tlla HT clreull becomH I.aYtacl.

A ,

.,.t_ '-

'or

The . )'111..... Incorpotales an .. Iectronlc advanc. 'Yll&m controlled by slgnlll from Imad).

2 Dlaconnect In.. HT lead from 0 .....ptlrk plug. Comtcl 1ha _ 10 • lpII'IiI*k plug

Ind lay lhe pllIfI on lhe 1Og1.... with IhIt Ihread. contacttng lhe .-.gl.... ( _ . . .trIIIon). If.-..-.....y. hold Itw - " plug ..." .. InIouIIIIad loot. W.,."lng, Do not ........... Illy of , ''''' apaIi" plug. from the ."""" • to perlon'n til" cIMck ,..., being pumpM 0111 of lhe _ .".,.

A

.,omINd

plu" IIo1e could Ig..ile, c.ullng

. e~ ....

...." :) Cllack IhIIllhII kill swllch It In 11'4 'RUN' poaliion and the t"n,mlssion " In .-tral. then IlIfT1 11'4 fIInItion switch ON and tum the ~ 0Itet0l'!he lIart. mot.... ~ Itwl'fStem It In good cond~1on I regular. t.1 bI ... tperk II\ouId t.. ...odItnt " IhIt plug MctrodII. W!hit Iptrk appear. thin or ~Iowllh. 0< I. non· a~~I"'I . '~rther Inv.stlgatton wHI be ~. TlIfT1tt.lgmionoll"""~thIt

The ')'Si em also Incorpoqtn • salety "'I.-Iock cln;uIt which WIll cut I".. ignibon W 11» ___ .00 It.,,~ Itw . . . . . II ruMIog and in getr. or W. 0 - ~ MIecIed

""*'

~ !hi engine II ......-..g end hllIoidestrd II exI.-.diId 11 ...., P'--" IhIt eng;.. from btoIng -.ted 1I1hIt.-.gina II In geer ......... hi crutch ..... 110 puIoId In 01 !tIeIr nllure. thlt Individual ignition II)'Ilem QOITIII(>r>eOI5 can be c!>IIcked but nol reptllred. !I ignl1ion syslem troubIM occ~r. Ind tn. I,ully compon .. nl can be Isolated. the only cufe lor the problem I, 10 rtpIIeoIl".. pII'1 with I new one. Keep In mind thll mOSI electrlc,1 ptr!s. one. purchlMd. COIMOI be ralurned. To .vold unn&C&aaaty .,.~. make vttry su.. 11'4 Ilutty comPOf*lI hIS """ P'*Ilvery ld.,t,1ltd btl'" buying I ~ P'f1.

-.

.y.tam In • 1og1c.1 fashion. II dner/bad

11'4 f&rvtIon triggers. the pk:k-up coil and Itw ~ poIIIIon.....,..~

no..-.

1 ,.. 01 acIjustrMnt II .......... II'I'f leIIo.n 01 hll'fStem ClIO be trIICed to ...... 01 • lI)'Item COIT1p:Ina"11 ... , sifnt:M .....trtng INt. O! the two poaibIities. Itw lin. II by ' - hi mo.l I"''''Y. In 1ha """"I 01 1.11vre. check 1ha

a.ca.....

A aImpIe Sp.ri IIIIP fe3;tinp tool ..... be ml~ 'rom 4 block of wood, I Itroe

a/llpator Clip Ind two Mils, Ona of

wh/eh"

t~ ""' that I tpII1r

phIQ

C4P or bl.. HT ~ IfI(/ cln be connaclacl 10 fhI and. ",.ka .u.. the glP be,...... tha two Mil MIfh '- the

-"-

_lot ...... - " plug In tum. • The Ignot;o" Iystem musl be atlI& 10 ~ I If*\< -..Nch II cap.bM 01 Jumpong I parllCllW atz. gap. 't'arnahII -oecitY It\tl , hNllhy .yst_ sI>ould prodllCtl • ~ capebIe 01 jump;r'Ig " lust 6 mm. A unpIe ~ tool ClIO t.. . . - to 11111 Itw minmo,rn QIf> ..... 0 ... which lhe sparl< wlN jump ( _ Tool TIp) ... .rt..wlYely II II ~ 10 buy .. IgMIon IIQIfk 9If> 1.. tool tnd some 01 ~ .... edjuIIabllt to artlN" 11'4 tperk II"P.

*

II Conn..::t one 01 the l!H-rI< plug HT ",.cj. from one coil 10 the protruding electrode on the I. ' tool • ...." dip hi tool to , good ...-lh (ground) on the ""!line 0< I"me (1M 1I1... trlllon). Ch&ck !hi! the kJll .wltCII II In !hit 'RUN' poIIIIon. 1Lm!he Igmion ~ ON IndILm the ............. on Itw . . . . . motor.

Ignition system 5- 3

U. DiM>onnKt the prtmary ~

3.5b ... _

.... ~ from .... ~ plugl

eonneoetors (....-o...cll !Yom the coli ••

"!tie lJYalem" In good condiIWXlI~. lit

bl~1 SPlrk Ihould bt SM'fl to jump the gap t>et_ the nail ends. Repeat the tMt IOf the

other

COHo

II the test

r"u~s

Ife good the

..,Ii.. Ignotlon aytItem can bt COI'IlIder.cl good. "tI'III--'< ~ thin Of )II'IowIIII, Of

..

non~t..,t.

lurtr>w .... _lig.tlOn WIll bt

. S IgnltlOl'l lauh. can bt CIIIIIgOIMs. namely _

'''Ied

<;Iri\ded

proballil IOUI'CfI oIlallu ... Work tl\rougtl the lilt eyst ..... tIcaIIy. refe<mg to the subIeQueot MClion. IOf lull delall, 01 the nee ......,. chII;b n IWb. Note, s.fotw c/'IIc;JOng !til IDIIr:wmr1 n.m. ....... tNt !til battwy ,. IuIIy chMflld If'Id 1l1li1 l1li tu_ ... III (pOd

"'"""'" u-.. b/

COfrOdad or.-.,.a "*1nII' COO'ItNCIJOI'II broken or s/IortIId wr«oQ ~ a'lY of !till componanr PMfI of l1li /gil/DOn IJ$1IOm (sea Chaprer 9)_ F#I(I/ty 1fT IIJed or spwI< p/Uf11;#f). IauIty apIrlI picJg. diIty. worn or CJOnT>dod pIuQ electrodll. or /tIcctrect ~ b e _

-

-""'by.y....... ......

Into two

wt.ar. the igMlOIl

system lin comp~~. and those which ... due to I parti.II."u.. _ The likely lauItI ... lilt"'" baIow. starting with !hi ~

~

d1 Faulty ,*,rr.', cMo'I or sidasland sw11!;:h, or ~ (WI cmptel' 9~ e) Faulty pid-1JfJ cojJ or damaged Iriggef. f) Faully If}nIrion 1fT ~ g) Fdy IgnIrIon ()()t>rroi..nl'. 7 "the_cI'IIICI
cJ F.uty ~ {mIir\I swtrd1 or enp'II , . ....rdI /Me Clwprer $

Ignition HT coils cOeck, rwnoval and installatKlfl

l:::

"

-.

Check

1 Check IhII coil ........" lor cracks a"'Id O!het

2 Tha pMIary a"'Id IICOfIdary coil _1InOM CWI be - . . . d with I nUtinwter M IoIows 3 RtornoviI 1M rider', Met 1_ Cflapter 8) Dis<:cn>ect IhII bMI-.y ~ (-wI lead 4 Tha.,.. ... mount"'" on the inside 01 the !rime behind the It-"'C! head - _ the I"'" tank end the SIr 1m. I\ouaing lor ItC<:eU 1_ CtIaptet 41 15 0r1 1993 srld 1994 YZF750R aod SP mod ..... tracl the wlnl'lg lrom the 0011 and dlS(:OI\I'I.cI ~ II the connector. 0r1 all other modeII., dlSCOnl'lolCt the prim..-y Cltcwt

llactrlcal cot\I"IICtOOl from the 00II 1_

1tIullraUon) On III modeII disconnect the HT lead, from thl Ip"k plugs 1 _ Ulultrillo n) . Mark the locations 0/ all wirl!! ...cI1eIds before ~Ing them. S Set tile met.,.. to the """" • t aclle arld - . . . . the resis_ ~ the pnnary Ql'CuIt ......... In the COil 11M 01 the wn.g c:otYIBCtor 11993 and 1Il90l VZF750R and SP modooIl) or on the cod termll'lllil (III other modeIIl 1_ iliullrlllon). TNI win give • -.nee readO"Ig 01 the potrnary windings 01 the 0011 arld should be con.!"ent with tile v.lue gIven in the Spscilicatl-ons at the begOlning 01 the ChIpt•. 7 To che<::k tile condition 01 the secondary WIfI(!Ings, ~ IhI spark plug "'IX from the HT _ _ and..c the_101M 1<-oI'Im KIM. eon.-..ct <>nil mel. probe to <>nil HT lead a"'Id a"'Id the 0CIw probe 10 the O!het INd and 1_ Mlultrallonl II the reading obtained is not -...thIn the rsngalhown In IhI Spscilicliions. II II ~katy that the coil I.

---

8 II the reading Is IS 1P«1I1ed. ITIfIUUnI the "llst.nea 01 the spark plug ClP by connecting the met .. ~ between the HT lead sockeIln the cap.-.d the --'< plug contlet In the cap 1_ mUltr.lIon). II the r-.g obtained II not alpecil\ld. repIaoe the --'< plug "'IX ....... ~ ~

• 3.7 To _

the _ coil ACOndary _ rllllatancl. connacI the IhI~pIug_

""""""*

5-4 Ignition system fairing tide panel 1_ ChapI. 8). and c:t1ICk Ih.al Ihll It not d...., 10 a damaged or broken wh from !he col to !he c:onn.:tor: t*IC:htd or ~ wIret C&'I --'Y be repIWed.

Renewal I R...,ova lhe rtd ..•. . . .1 (see Cflapt. I). ~ !he batlety Mgallve (-ve) 1N:l. 7 Remove the !uti tank ( _ Chapt..- "). tn. 1<1_ falrlng and 1111 right-hand laIrIng aiel, PItIII 1_ Chapter 8). s Trace Iht wiring from tile pock·up coli on

t II eitl>er coli 110 confirmed 10 be faulty. ~ must be repIacId wfth , ..w ....: 1M coils . . - * I ~..,.;I c.nnot II'IereII;n be ""PI'hd.

Removal 10 Remo~e lhe "al (SH Cheple.- 8). DiIconnecI 1M Dattery negatIw (......) '-I. ti the ~ . . mounted on 1M n.kIe 01 1M hme beIWId the .. ~ r-=:I - NInOYe 1M fuei tank..,.;l 1M ""'-"'II lor ~ (-~").

"fiII.

1:1 On 1993 Md 1994 YZF750R end SP models. lrace lhe wiring I,om Ih. coil and dlt-oonnect it at the C(NIfIfIClor. On all Oll>er rnodeb. dlKon.--! primary cireuit ~ COIW'IK!ono from lhe coli ( _ Illustration 3.510,. On .. modele d~ I.... HT fea<;.lIon, 01 all

I....

wIret..,.;lluds ~ ~Iing

tt.n.

13 On 19113 and 19!i-' YZFtSOfl. and SP models • . - - the IIrap Heuring the coli and removtl lhe coli. On aU 0I1>er YZF750A - ' SP ~ "'- 1M coil ofIlb mcultIrIg

bracket

I'" IlIult.llt!on). On YZFI()I)(lI'I lhe screws securtng tn. coil

~ •••tmO\IfI

and r""", ... tile coil,... IHuttratlon). Nole the routing of tha HT _ .

HT,.... ..

Mak_ ."'" tn. wiring con"..;tono and oec:ureiy~.

II u.-.cr-!he 00b -..trIg !he pO:Ic-up col and III wiring clamp and withdraw IhI coil from the engine lseeUlustrationl. DIscard the

Piek-up coIIcheck I\f\d renewal

0-."

14 InsteliallOO Is lila ......... of removal.

10 Apply some claan engi ... 01110 lhe new F~ the col Into !he ....... ..-.d ~I'" I;ha bolts .-.d tha wiring clamp bolt to the lorq...., HIt:Ing spacifled at In. beginning of lhe chaplet. Feed Ih' wifing Ihrough 10 111. conf">IClor, HCurtng ~ with any ell"" or Ile!I and malting ltD Hill COITfICIIy rout«I • .-.d rfICCIIYIIO;I ~ , 1 11'111111 the fuel lank ( _ Chapler "I and !he 18img . . . . t - Chapter 8).

O-mg - ' iii. it onlO tha pO:Ic-up col.

Check 1 Ra!ncow tM rider', teal I.... Chapl.. a). DiacQnnec11ha betlory negatt... 1""'fII '-I. :I ~ lila fuei IW\k 1_ Chapl..- "). 3 Trace 1M wlrtng from the plck·up coil on 1M r!gh1-1IarMj 8Id. 01 tM engine and di...onnecl it ., !he whit, 2-pIn connector in8Ide the rubber boo! abo-.. the C<WIkc:aH I _ lIIuatratlo<>l. Utlng a muitima!. HI 10 tM atom. x 100 1CaMI. ITIIIaSI.n the _tanoe ~!he terminal, on 1M pick.up coil tide of I;ha cornector. • Compare 1M _ding obtllned witi'! that v..ninlhll~lIIl;ha~of

Ihl, Ch.aptet. The pick-up coil mull be rlPIactd with a r.aw DOtI II thl rNodlng obtained differ. graally from Ihal gl .. en, Pl'r1icularty If IhI m.,e.- indlca'n a thort circ>Jt (no -..aDIt noIOSIa'lCej or l1l'i Open circuit (infinite. or wry high ____ II N IhII pick-up col _thought to be 1auIty. tnt ~ the Iowtr 'alrtr\g and the rtghl-h.and ~

Installation

IhI rtghl-hand tidt 01 lhe engine and dllCOflntCl it 1\ Ihe whit. 2-pln connactor Intlde Ih. rubber bool .bo... lhe crankca" 1_ lllul"'tion ".3). Fa.::t \he wiring back to the coil. noting Itt ~ and I'8Ieasing h from eI"'I dIC:. or __

C"'"'.

1 II the "SIS el>own In Ih. practdlng

Of

IoIlo-Mng SKtionl M ... 1.,1ttd 10 IaoIIora the " . . . of an ign/IIon 1aA!. h Is poaib!IlMI the Igoltlon control unit ~MII Is lautty No " " <MIaiIs . . ~ with which tha IriI can be

-~.

Ignition system 5-5

·R·e~m~o~v~.~/~~~~~~~~~~w:..,~.~m;'..,..""~...:••:.~...::~,~",~...~~~;;:::::;::::::::::::::: 2 Remove the .Ide'" Hal (S&& Chapter 8). Oi!Iconn&Cl the battery negative (-vel lead. On

for regular checks: ont)t H InWlllliOBting a faoll such as a "'" 01 power or. misfire. shoold

VZFl000R models, remoV9 the tu&il8llk ( Chapt.,. 4) 3 Disoonn&ct the wiling COOI"I&CtOfS from the ~nitioo control unrt ( _ llIuslr1rtions) 4 Remove the ",;r&W(s) II&Curlng the ignition control unit and rftmOve the unrt (S" 111''''''01100).

dynamic:ally (engine ",nnlng) ualng a 8iroboacopl<: lamp. The Ine" peosi~ neon lampa should be adequate In theory. but In p'actl<:e may ~ D pu~ 01 such low intenstry that the tim ing mark .emains Indistinct. If po55ible. one of the more p'''''ise xenon tuba lamp' should be used. powereel by an extem,l SQu.~ 01 the appropriate voltage. Note: Do nol uUl the mectl/ne's own batt"')' as "" incormct resdl"'J may rewlt from slray Impulsl!>s w/lllin Ille ~chlne'! 1!>1e<;I,i<:al

Installation 5 Insl8llation is the reverse of ,"""""ai. MaI<e sure the wirlng COOl1e<:tOfS are correctly and II&CUr&Iy connected.

6 Ignition timing general information and check

General information

~

iI:

~

~~~~=i~ ~ked

.,,-

Check 3 Warm the q

lnl!> up to no.mal operating temperature Ihen stop ~. Remo~ the lower fairing (!1M Chapter 8). 4 Unscrew thl!> timing Insp&<:tion pjug from !he left-hand side of the engine (see

5.. . • and mounting screw (a
S The mark on the cranl<shaft which indicates the firing point at klle speed for the No.1 cylinder 15 an 'H' marI
""'**'

5

5- 6 Ignition system 2 When the ign~lon is first switched ON. or while the engine ie runling. the tlYottie position ~s own saIf-diagnosis In the 9IIent of failure or taulty wiring. Whan a f;wH occurs. the tachometer wII be seen to display zero rpm for 3 seconds. then 10,000 rpm (YZF750R and SP modals) or 3000 rpm (VZFl000R models) for 2.5 MCGn
sensor perlonntl

Check 7.3

Throm. position .....101' (arrowed) VZFIOQOR modeI!hown

e Con.-;t th" timing Hght to th" No. I cyllnd"r liT I"ad as described in th" manufactur..... instructions. 7 Start th" engln" and aim th" light at th" static fuling mark.

8 With tha machlna Idling al th" specified speed, the static timing mark ahould point ~ tile uprights 01 the 'H'. II Slowly Increase the engine speed whilst obsflfVing the 'H' mark. TIle mark ahould move clockwl .... Increasing In reiat>on to the engine speed Ul"tf H raaches full advanc" (no ldantilication mark). 10 As already stated. thera is no means of adjustment 01 tha Ign~ion timing on th ...... machines. " tile ignition timing is Incorrect. or suspected 01 being in<:orrecl. on" 01 th" ignition systam compooen" Is st fault, and the system rr;..J$t be t... tad as dasalbed in the pr'808ding Sact>ons of tIlie Chapter. 11 When the check I; complete, Install the timing inspection plug and tighten H securely.

7 Throttle poaition s.tSOr check, adjustment and renewal

~ ~ ~

Note: The t/lfolfle pos/Iion sensor is fittBd !O 1995-on European YZF75CR. 1111 YZF750SP IIIId l1li YZFfOOOR models. 1 The throttle position sensor (TPS) Is mounted on the outside 01 the fight-hand C8/tlUr1!ttor and Is keyed !O the throttle shaft. The sensor pt"ovkles the ignition control unit with Intormation on tjUOt~ pOSition and rate 01 opening or closing.

3 Remove the fu-el tank and the air filter houaing (see Chapter 4). The t/lfotU" sensor is mounted on th" outsm of th" rlght·hand carburettor (SH Illustnltlon). 4 Make W'tI the ignition Is swilchad OFF. then disconnect the SSlSOr's wiring connector (SH MIUS1ration). Using an ohmmeter or fOOmmeter sat to the K-oI1rros r&I"1g8. measure the,..-.sor ma>clmum resistance by connecting the meter probelI beIweerl the 1>100 and black (yZF75Of1 and SP models) or blacWue (yZF1000R models) wire terminals on the $8nSOf skIa of the conr.ector. Now measura the resistance ratlQII by conr.ectlng tllfl meter probes between the yellow and iliaci< (YZF750R and SP models) or bIacl<JbIve (YZFlOOOR models) wire terminals on the connector. and slowly opening the throttle from fully closed to fully open. If the readings obtained differ I,om those specilled at th_ beginning of the Croepter. ropIaoe!he ser\SOI" with a MW 008. S If tha readings were as specified. using a multlmeter set to resistance or a continuity tester. check for continuity belw"" the terrninaks on the wiring loom siOe of the sensor wiring connector and the corresponding terminals on the ignition control unit connector, roIerttng to the WIring Diagrams at the end 01 Chapler 9 (first d;sconnect 11). Thera should be continuity belWMII each terminal." not, this Is probably due to a damaged or broken wire ~ the COfYIOCt""" pn:hod or broken wires can usually be repaired. Also check the connectors for loose or corroded terminals, and check the SIInsor I!SIIII for cracks and oth ... damage. If the wiring and connectors are good. check the adj...stment of the sensor as des<:til-' below. 6 If the S8O!I()f is suspected of being faulty. take k to a Yamaha dealer forluft/ler testing. If ~ Is COI1Iirmod to be laulty, ~ must be mpIacod WIth a new ona: the sensor ia a Haled un~ and cannot therefore be repair9
Adjustment 1993 and 1004 VZF750SP models

7.4 Disconnect the TPS wiring connector ("rrowed)

7 BefOfll edjusting the sensor, check the idle speed and earburottor synchronisation (see cnapt ... I). 8 Remove the fuel tsnk and the air tiller hOUSing (see Chepter 4). Tum the Ignition switch ON. than disconoact the sensor wiring connector ' ..a illustration 7.4) . Using an ohmmeter or multimeler SlIt to the K-ohms

range, connect the meter pt"oOes between the black wire termjnals on the $
yeUow and

All other modela 10 Gefore adlJSllng the sensor, check tha Idle speed and carbureUor synchronisation (_Chap terl ~

11 Remove t~e fuel tank and the air filler housing (sea Chapter 4). Tum tho Ign"lon switch ON, then dIsconnect and re<:onnecl the sensor wiring connector (se. Illustration 7.4). This $O~ the 9n'tion <XlOtroi unrt to 'sensor adjustment m<>
Renewal 13 Remove the luel tank and the air filter housing (sea Cl"Iapter 4). The Ihrottla sensor is mounted On t1e outslda 01 the right-hsnd carbI.Irattor (SH IUustration 7.3). 14 Disconnect the wiring connector. then unSCrew Ihe sensor mounting acrew' snd remove the sensor. noting how Illi18 ,sea lIIust.atlon 7.4). Unless an angled screwdriver Is available. ~ may be nacassary 10 displace the carburaltors to access the scrawa (see CIlapter 4). 15 Install the sensor and lightly tighten the screws. then connect the wIring connactor and adjust the sensor as described above until lhe correct reading Is obtained. On completion, tight"" tha scrllWS 9II1Kl1y and a little at a time. 16 Install the air Mer housing and fuaI tank

(_cnapt... 4 ~

6-' Chapter 6 Frame, suspension and final drive Contents Drtve chain and sprockets - check, adjuS~1 and lubrication. . ..........see Chapler 1 Drive chain - ~ .... cleaning and Installation .•...•...•...•.. 15 FOOI,"IS. brake pedal and gearcllarlQ8 Ie
Sidestand switch - cIleck and renewal . . ...........see Chapter 9 Skiestand - check .

. . _ Chapter 1

ForI<s - ~ and Installation . B Frame -In&pection and.&paW . 2 General infonnalJQn , , i'iandIebar ,witches - check . . ......... _ ChaptM 9 fWldO!obar switclleol - .emovlll and InslailationSM .•...•. Chapter 9 Hano:Ik!Ilan and ""'"'" - removal and Installation . 5

$kkIsland - lulYlcation • , ..•................see Chapter 1 Sidesland - removal and Installation . 4 Sprockels - check and renewal ... 16 $t~ head beatings _lfgePIay check and adjustment ..•...•.......................... " " Chapter 1 Sl~ head bearings -Inspection and renewal . 9 Steering head bearings - lubrication. . ........... _ CtIspt8r 1 SteMng stem - removal and InstaiJat.,., . 8 Suspansion _ adIUSimer1\$ . . ........ 12 SUspension _ check ................................... Chapter 1 Swingarm and """P""sion linkage bearings -

Rear shock absotbef - removal, inspection and Installation. . 10 Rear sprocket coupling/rubber dampers , ......•...•. 17 Roor suspension ~nkage - r9ffi0VaJ. InSpection and installation. . 11

Iubrlc8!1on , .see Ctlapter 1 Swlngarm -Impectioo and b8arIng renewal ................... 14 $wingarm _ r9ffi0Val and ins1allalion . . .... 13

Degrees of difficulty

Specifications Front forks Fork oiI1ype . Fork OIl capacity

Yamaha suspension oil ·01' ... fIQOIvaIMl

1993 VZF750A models. 1!K14 YZF750A models. 1995-<>1\ YZF750A models 1993 and 1994 VZF750SP models . 1995-<>1\ YZF7SOSP models . 1996 YZF1000A models . 1997-<>1\ YZF1000A rTIOdeb . Fork oil level' 1993 YZF750A models . 1994 YZF750A models • 1995·011 VZF750A models 1993 and 1!K14 YZF750SP models 1995-on YZFlSOSP models . 1996 YZF1000A models . 1997-<>1\ VZFl000A models . Fork Spring , ..... IIIrlgth YZF750A models

"'~ ."'~ .,,~

".~

471 cc

""~

""~

,,~

123mm

""~

'''"''"'' .

StI
YZF750SP models Slandard .

259mm

S
,..~

1996 VZFl000A models

''"'""''' .

$er\Oce 11rn~

.

1997-<>1\ VZF1000A models Standsrd • 287 mm Service r",,~ . 2B4 mm "01/ _ is mMSIJr&d from the lOp of rile lUbe wirh !ha fori< spIing remo'lftd IJfId Ihe ifJg MIy oompt9SSI1d.

•

6- 2 Frame, suspension and final drive Rear suspension Shock _

spring tr.... 1ength

1993 and 1994 YZF750R models

S""""'.

216mm 211.5mm

SMvic_Iim~

1995-00 YZF750R models S~andard " . Service Iim~ . 1993 and 1994 VZF750SP rTIOd
""'mm 196mm

"" mm

215.5mm 160mm 157mm

196mm 164mm

Final drive Chain type YZF750R models YZF750SP models VZFl000R models

KAVDAlOO 532ZlV (106 Wnks) KAl/DAlOO 532ZlV (104 links) KAVDAlOO 532ZlV (110 i nks)

Torque wrench setting s Foolrflst bracket bolls Steering stem nul . Handlebar pos;t\oning bolls . Handlebar to N>Idoor boll (1996 VZFl000R models) . Handlebar holder clamp bolls YZF750R and SP models . YZF1000R models Handlebar end-weights

28Nm 110Nm 13Nm 28Nm

VZF7SOR and SP models . VZFHXXlt'l models FOt!< clamp bolts {lop yoke)

2lNm 21 Nm

VZF750R and SP models .

25Nm "Nm

VZF1000R models FOt!< clamp bolts (bottom yoke) VZF750R and SP models . VZFl000A models

13Nm 17 Nm

23Nm 23 Nm

Damper C&'tridoge Alleo boll YZF750A and SP models . VZFl000R models Camper cartridge to top boll locknut (yZF75OR and SP models) FotI< top boll YZF750R end SP models . YZF1000R models St~"II stem nul • .. • . Ae¥ shoe!< absorber nuts Rear suspension linkage arm end linkage rod nuts . Swlngarm pivot bolt nut • .

R...... bt""e torque arm nuts .

"'Nm "Nm 15Nm 23 Nm 25 Nm 110Nm "'Nm "Nm 125Nm "'Nm

Front s.proc:kst nut

YZF750A and SP models .

YZF1000R models ............ • .. • .. . ... . ...... • Front sprocket cover bolls • . Rear sprocket nl.llS .

70Nm "'Nm 10Nm "'Nm

st.........cJmem~.

1

0eneraI1nIonnatIon

All models u se II twin s par box-section aluminium 1m"", wh"", uses !he engine as a

Front suspene.lon is by a pair of oit-damped telescopic forl<.s which use a cartridge-type damper. YZF150R and SP models have upside-down l orks_ On al l modelS the forks are adjustable lor !!pring pre· load and both rebound and compressiorl damping.

At t he rear, an aluminium alloy swingarm acts on a single shocl< at>sorbe< via a ~hree ­ way linkage. The shock absorber Is adjustable I", spring pre-Ioad and I", both rebound and compression dampmg. The OOWl to Ihe mar

....-.

~

Is by chain and

Frame, suspension and final d rive 6- 3

3 'and_ ....k._ gearchange lever ~

F"",, inspecbon and repair

. ~ ~

removal and installation 1 The fr.... $hoUId

un-..

not

NqIJire

._wa!

,n..tlon

ICC!dent " ....... Ills OCCutr.d. tn mOIl CUM. fr_ is Ille only ut!tllClory ........:Iy for 8UCh damIge. A ' fr..". apecllollstl hlv, IhI jigs and othtlr .cjuipment nICIUafy lor . t '~ h tenlng IhI tram. 10 the flQulfld ,tandard of accuracy. but ev.n Ihlll th .... I, no simple way of auesaing 10 what .~tlfll lhe fr........ may hIIv. bean " 2 After the I'\'IIdIIne 11M lOCUn'IUIaIed • lot 01 mIIIt. the Iramt thouId be ...-ninId cIoeIty lor ~ of
,ITIIMCI.

~~ontn._..,naIlnI<1I

hCllnwge, but ~ II. task lor WI ~ 3 Rlmlmblr 1l'1li I frlme wtlich ill out of

alignmenl will !;IUM handling probllma. 11 ~ II lUIPICIed .. tn. .-.II of WI accidInt. It will be n-...y 10 strip IhI rnacI1ll11 eompllt-'Y ID the frame can be 1IIDr<1ugNy c:hIcked.

Footred. Removal ~ rider'1 footrests I To _ the r\vhI-hlnCllootrISl, UI1ICI'IW lhe boll, lIICuring the 1001'''51 bracket and lIiaplac. It lUll enovgIIlO provIOe &CCMa 10 11"11 footresl "'" on the b6ck 1_ ~Iu strllllon) . Makl ...... no I lr'Iin .. placid on "'" ~riog or brak_ hO_. Un8Cfew 11>8 nut and ~at_ the fooU." f.om 1111 bracket IH. IIlullntlon) Till footr..1 rubber !;In ba "'"tachId from till footresl by nmovIng till _ _ !hf,t IICU'IIt 10 till fooIrIIl. 2 TO_hle/!·I\Ino:IIQQb"",._ 11'11 IlIA from 11'11 b6ck 01 the _ _ tncItIt . . , MPallle till fOOl'1S1 from till bracket ( _ . . .trMIon,I. The footrest nJbbar CIf\ be ~ by .....cMng the IQ'IIWS thM MC\n " 10 the Iootrlllt. Removal - paneng.or fOOtrests

3 On 1m YZF750R models,""""" the tpI/I pin from 1111 OOllom o f 11>8 pi¥Ol pin . 11'1.. wltllClnlw 1111 pivot pin a nd .emove 1111

noting the fitting of 11'11 del"" pIiIM baH .., tpring - take C¥I tl>el they ~ noI tIlIlootrest.

tooInooII.

IPI1ng OJ! _ 4 On

..

~

0Il>10'

VZFf::.oA

MOOIIS

and

VZFlDOOR onodIII;, UIISCNW the nullram 11'11 botlom 01 \III IoottISI pI'IOI boll. then Wlthdrlw 1111 boll anCI """""' \lll1oott1ll. noting the Ii!ting 0111'11 deterrl pIa\M. bill .., tpIng - gkI .,.,.. thai they do not oping out _ fW'\'\QWIg the foo\r'l$l 1111 illustrlltlonJ. AIID not. Ihe cojla. for the pivot boll on VZF'15OR modeII. Inllallatlon 5 InIttlllltlon it thl _ _ of fIIITIO'iW. Instlllng IhI r\vhI,/Iand froot 1oot!tIst, tigtrlltIt 1111 brac:ket bolt, 10 the IQI'q.... ",Ung IPIdI\Id 1111'11 beginnO'>g 01 the ~_

""'*'

Snlk_lMdaJ

R_""

• ~ \III1pIiI pin II'Id wa&hIr from the deYII pin IIc:UMg \III """" pedal to the

masler ~ puahrod 1_ IIIvWItIQf'I) AIITlOYI Ille cleVIs pin and ~II the pua/VOd from 1111 ped .... Unsc..w \III pedal pivot boll .., .1IT1DYI thtI pedal. freeing till tnkI pedII ret ...... IPI1ng aod 11'11 brake tigItI swkc~ IpI\ng lrom lhalug on IhI pedal. Ind

• 3.1!a R.......... ItII.ptc and w",*" to\)...., _ w h cIIwiI pin (B)

6-4 Frame, suspension and final drive

noting It1e wave wash« on the outside and It1e plain washer on It1e Inside (see Illustration) . Installation

7 Installation is the reverse 01 removaJ. noting the following: .; Apply ~ 10 the broke ped8J pivot. b) Tighten the ped8J pivot bolt seclJreiy. c) Use I new split pin on the clevis pin securing the brake pedal 10 the""",Mr cy6nder pushrod. d) Check tile opetatiofl of the IN/" bIlI/QI/if1h1 switch (see C/l8prar I).

to the footrest. Unscrew the lever pivot bolt and rllr\""lOVe the lev .... , noting the washNtl on the outsld
GeBrchange leller

Installation

Remollal 8 To remove the lever on its own. &lackeo the

10 Install ation Is the ",verse of removal, rooting the following: .; Apply greasCUt"eIy. d) Adjust the gear Iev8r hejght as mquired by sctewing the rod in or out of the ifwer SlId arm. TJgIlten the Ioclmuts secursly (s_ illus tration 3.88)

gearcllange ~ver Iinkaga rod loc knuts. then unscrew the rod and separate it from the lev.... and the arm (the rod Is r""8f!I ... threa~ on one end and so wil l simuHaneousty unscrew from both lever and arm when turned In the one direc!lon) (see illustration). NoM how tar the rod is thrfIad.8d into the """" and arm Ill! this determines the height ot the """" ntlative

3.9 Unscrew tI>e bolt (AI and " Ida ~ """ oft the shaft, notlnll lhe alignm&nt manu. (8)

4 Sideotand removal and installation

~ ~

'"

1 Support the motorcycle ,"",urely in an upright position using an aUloliary stand. 2 Unhool<. the stand 1I¢"I1'I and remove the link plate for the sidestand switch, root~ how it fits (see illustration), Count ...·nokI the pi"'" bolt and unscrew the nut on the inside 01 the bracket. Afornove the pIvol bolt and the Sland. • On install allon apply greaM to the pivot and to the contact wrtaces 01 the stand and bracket. Apply a ,ultable non-perm an ... t thresd k>cl
• •2 Sidestand sc:>riI1llS (AI, link plate (8) end p/IIot bolt (C)

Frame, suspension and final drive 6-5

5 H~and'--' remoY81 and installatton

. ~

:t:::

Handl.bars Remov,1 Holr. no.~ C&'I bIt~ from . . , cI ftIe ...... « ...nrch -..b/iM. , RemoYe 1M lalring ~ ChtrpI..- 8), ...cI on YZ!'10C0A modIIB !he Iu8I tank (Me Chaoter 4). ~ "- bQII:I ae<:Uing !he stay 10 the tank br.,;k~ (YZF75OR and SP modeII) or Ira",. (YZFl0C0A models) and _ the stay I -

.". !gp ~ wIIhoof n.wJQ 10 _

OWl""'"

to detacl\ the Cllbl. . from 1M carour.tlora. ~the~IJWi!dl{.... ~'l .

............. Ncq, faOotlg on .". bIQ /I tWqUIted. though If illItMubJe 10

n... 110 no ~ 10 dIIccrolIct lhlioom wiring

""""10".--., ftIe~cI~

3 "1"IfIIOYIng the 11ft hIrdICIr. dIIpIKIf the clutch "...t. cy!1tIder and .--voIr ,... 0-..". 2). ThIN 110 no.--:l 10 disconnIc:t tne IIydrauIic: hoM. Keep !he .......... uptight to preYerll ~ fluid INkIIoe .00 makI ...... no . t,aln III plac«I on the l\ydrau Oc hoH(l). ~e the handleber switch (see Chapter 9) and the chok, CIIbIe (_ Ckap!er 4). ThIr1I 110 no need to o:tiI<:onnIcI thewting conoector. 4 1/ necesaary, remove till IwIndiebar Indweight /Tom the _ of the hlnd l _ and ' .......... the grip - the weigh'" themM/Yw

no.

1.")VU . . . t~.".~_.". ........ '""'"'",.. CI>Ip/W IU. _ _

II.- IattIg SIlly. dIoscribed. 2 If I"II"I"ICMng the right hI/IdW:IIr, ~ the fron1 InI
~.

tlvead Into the handlebars , _ liluetratlon). H "'-Y bit ~ 10 ell! open 1111 left-hand grip o..oeIng s shatp bI8dIln order to ~ M .. tIwy . . ........m.. Mudlin pIaoI. though a _ _ driv.. 1Mtw..... ttM gnp and the and lIit«spray

00_. ~

_~

wi.

IubriCIIot direcl ed 1n10 the grlp usuall'y worlt. Depending on you, _vII metllod ...cI ~. 1I.IOCe$S, S new grip "'-Y 1)01 I1IQUAd

~ Removto the bIrilng Cllpelrom the '-do of the hlndle-bar positioning bolts using s ......, lIat-bIaOed screwdrN ... then unscrew !he bolts (Me iII...-IoM). AlKlIIacI<.en the forir. ct.mp bolts In 1111 lop yoke 1_

~.

u..c:r.wlha ~ "."

r-..t

•

6.6 Frame, suspension and final drive

and . _ It along ... I~ Ita waaher, wlIerto I~I«I 1_ Illuatratlonj, Gently ease the lop yoke upw.ro. off In. fori< tut.. ...." P'*IIOn ~ a..,.-Inga rag to pn;>I..:t theWlkorocr.... ~ (_ ....tratIonj

I On teee Y2FtOOOA....,.,., ~.........tng the ~ Iero\'>g In. holder in pIaaI, ........... In. blinkIng ClIp from the I....... end 01 the ""nd~, t'*> untc._ tile •• Iaoning bOlt ....".wcs. the bw out 01 the holder, noting how II locItl.., 7 On _I I otller mod,It (and on 1996 YZF1~ modeIto ~ removing the handlebar .nd hold .. togetllerj .Iackan the handl"bIlr holder clarnp bottlt) ( _ illustration S.5c or
'"-

~

.r On 191M YZFIOOORmodeIt, 1f$ClJ*l!ed,

........... It. . , on It. ..... .nd 01". ~~ cotrKfIywlth 1M CQI ....... dIi .. I!Itlh IMhdder, T/gI'4en 1M ~ to tIOkW bolito !he IO
"""'"

$"""

b) 11g/'Ir.'1 1M .re.Ing nul. IorIr ~ bolla. /wII:J/etw fIOIIlioning boll,

~~b0it3,.ro

1M endW1IighIs It..........-:l, to /he IO
.".cJ1Jed al/he ~ 0I/he CIIIpter,

--.

h".,,,,,, c} FWw to ". .......... CIIoIpIws as ~ ~Ihe ~Donol"'~

d) Do not foo'pIM 10 recomoecI lhel'ronl brlI/Ie IfIhl twIk:h MId dJ!d! switch ~

....-,

8 FOfb removal and installation

wmv

Al;ftnf ttorom. ~ IrfItIPbrII-

CNpterlj, f} Check /tHO """",tiao! 01 all swilches .ro I'" I'ronl braI!e &nO' clutch bel<:w 1Min{; mec/WIe on the fOIKJ.

I'"

Front brake leller and clutch lever

Remolla' Caution,

AIt~0"9h not strictly "ec.llary, balrnw ramovl"9 tha fori<. It I. recommended thaI lhe la;,;"9 .Ida 1M~ -..d/or tltlrlrog ara ramo...d tIM Chapter 8J. TNt will prwatIt ecc:/denUI ~ 10 Ihe

--

I A..nova 111. failing and the f.1rIng 110.

R~.

t l..Iow:Nw the ..... pivot ICfeW IocknuI. u~ the pivot 1CfeW....:I slide the ..... out ( _ lIIuatratlonj Taka cats not 10 _ the pushrod buah from Itl ..:>ekel in the clulC~

- g._

bracket When Installing lhe clulch )evfw, ......... the .-.d 01 tha pushn:Id iocIII" In \ha ...... 1n tha bueh """""'" In tha ..... 1_

I*'*' (aM ChIp!.- 81, 2 0i:IpIM:, the front brake CllIi9WS 1_ c::t.pw 7). no.. _ no ANd to diIoconnect the hychuIc _ from the ~

3 AerrIc!WIIhIo from ....... ( _ Chapt. 7). • Remove lhe lronl mudgUllrd ( _

I nstallatlon 10 I".,.n,IIon 111 ,he .everse 01 removar. A.wi'I to In. pivot bOlt shall 8nd the

a - •.

contact ..... betw"" the lever and II,

illustration 5.5c

5 WOI'k on each fOl'k 1rdMduaIIy, Slacl<1I'I tha

handleba.

hold" Of

clamp

bo~(.)

I'"

d) , ReIaua the Cllble II,

5.10 When inltalJntlthe dutch ........, til: the pushrocl IAI Into the hole In the bush (8)

Frame, suspension and final drive 6-7

arO<.md tlla top of th(l fork woo. notlog tha routiPlg of the wire (see Illustration). AI$O octa

th(l roullng of Iha various cabt&$ and hO%Ol arour>d the to!1<s 6 Stack"" the fOIl< ctamp bolt In the top yoIIa (Me ltI'"lr8tioo 5.50 or dI. It Ille lorks are to be dlsassembJed, or If tile fork 011 I~ b<:Iing changed, It il advisable to slack"", tile lork top bot! at tills st81/&. 7 No1(lthe atlgomeot or amount 01 protrusion of the lapa of the Tork lube wfth tile top yoke. Slacken bUT do oot remOve the lork clamp bolts In tile bottom )'01<11. and r~ the fori<

twisting it and pulling it downwards (see Illustrations). Secure the handlebar assembly thaI the mast", cylinder ......... oif remajos upright. making .... e ~ is no strain on tile

by

$0

hO$Il or

w..v.g.

IN ~ •

lithe fori< tegs a ... seized /" the yoka5, spray the "rea with perretrating oil "ftow lima for It to SOlIk In

."d

ba,.".t'YIIIg~In.

Installat,on 8 Remo .... all traces of corrosion lrom tils and hoses are lhe correct side of tile fO<1< as noted on removal (see illustration 8.7b). Check Illat tile amount of ptoln.lslon of the fori< tube above the top yoke Is as noted OIl removal and equal on both oidos - the tops of the tubes should be Hush wilh the top of the top yoke illustration 5.50 or dI . g Tight"" the 100< clamp bolts In the bottom yoke to tn. torque setting specified at the

,s..

beginning 01 the ChaptBf (see illus tration 6.78) If the tork leg has beetl dismantled or d the fori< oil """ been cIIanged, the fori< top bolt should now be tightened to the specmed torque setting (He illus tration) .

Now t>ghten tha 10rk c lamp bolt in the top )'OI<e. and the handlebar hoider clamp boIl(S), 10 Ihe specified torque settings (Me

lIIust.atlonl). Secure the wi.lng to Ihe fo.k using Ihe cable tie (see Illustration &.5) Note: DependIng on the tools llvallable, It may be 118(:&$$111)' 10 romo"" llIe ~.ndlll/].ar po$lfIorliIIfI boItl/l'ld sJid$ the hllndIt1bat down the fOOr In orrJ&r to Qllin deanJnce fo<' II IotQue wronc~. Refer 10 SlIClion 5 for delails and iIIusfrelions. If Ihi. is done, lightlln IIIe handlebllr ~ifioning boil bflfo,. llIe handlebar cJI/mp bolt. 10 INtail the fronl wt>eeIlsee Chapter 7). the front mudguard lsee Chapler B). and the braka ca lipers (see Chapter 7). Make lura lhe speedometer cable is correctly routed,

"

Install Ihe lalrlng and Ihe fairing , ;de

panels (see Chapler B). 12 Check tile ~11oo 01 the from fOIl<. and braI<". Ilefora taking lhe madline oo! on the

..,

8

6.96 If slack"",ed, tight"" the fork top bolt to the specified torque

6.9b Itght"" the fork clamp bolt.

!I.1k: • .. and thII handlabar clamp boIt(s) to

tile apecified torqua

6- a Frame, suspension and final drive

~

7 Forb -

~~~

~

YZF750R and SP motIftl. Disa.-nbly , ......... ~thelor1
u-... uu.ing an

...,.,.."t«ll1ll.oI_. Store"compooentI In serw.t •• elHrty marlted eonl.l..... ( _ iIIustraUon). Due to the cor.truc:IIon 0I1MM IOfb • .,. ..... r.rn and , apter-I 1001 I" rIQUiIWI (_ S1ep 5). 2 8elore ditmlntllng the 1oOc. 1\ .. edlflHd !hat the dIrnpIr CIrtridge boll bot ~ at this 1taQI. Compress the out. lor\( tubl over IhI! Inner lub
,.nt

~Ide tile 001. lube lully down onlo the Inner tub
and

0lIl. tur. to I"I'W\IrnIse oil

~)

wtIiIe. wId1

rod AI .... boll

7.' From IoriI DIIfTIPOIWftts _ VZF750R .nd lIP model.

1 Top bolt ass.nb'Y

, ,-., 2 """"

...... """"'

"".-

rrm...:ll994~

7 SHcJ. w....... (Im ...:l 1994 models)

,,-

"".,.. , ...........

110iI . . . 12 ReIaWngo ~

13 Dt4r Ma' 14 o.mpwc:artri(lge 15 Topbush 16 /liner rvbe

""'--

17 o.n.-~ bolt

Fram e, suspension and final dri ve 6 a9

1 .511 "home-mllde tool can boo m_ as

1.51:1 Fit the tool 1",0 the t>oIes In tile spacer DB ahown

-~

1.8 R..... o ... the tOp bolt assambly as o."""",,

the aid of an aSSIstant il neeess-aoy. keeping the damper cartfldQ8 fully e . tended. Obtain

-'!her the Yarnahoo --..it::e tool (Pt. No. 9OBOO01441). or construct • I"Iorne-made equilialent f,om a piece 01 a.eel Sleap bani Into a U-ahape. some threaded rod and nuta, DB shown , _ illustration) . n the tOO onlo the spacer. kx.I.Ur>g It Into the """'" ISM llIuSt,atlon). Push down on the $p6C9I" using the tool and have an assistant Inset! a Utab/)' _ washer With a slot cut Into ~ bet-. the lOp 01 the spac. and the base 01 the locknut on the dM1per eartrid!/e (_ Illustration). Thb .... n keep the apace!" and spring compressed while r.noving the lOp boll ~ 8 Using two spanners. one on the locknut anct one on the lork tOp 00It. counter-hold the tOp 00It and slacken the locknut. and thread ~ to the base oflt~ threa-load adjusterftop bo~

7.1a Withdraw the sprirIli .

7.rb .. . then wlth
aSSMtbly off the
care to retrievl!o the washen from the 011 ~ they fall 001. 0ItlerwIH. pjck th8m off the t"" 01 thtI damper when RIs ........,.,,1Id. 9 I~ 1IMI fori< leg over a "-"table container

stowry--spnng~- ~

.. nd pump .h .. I"'" anCl ClamPfll" cart,ldg. vlgorousfy to •• pel u much fOfk 011 as po6Sible. 10 Rtornow 1IMI preW>usIy sjackened damper cMt\clge bolt and Its seaHng wasl>er from thtI

have an assistant ,emove th. fabricated ,totted washe, (see Illustration 1 .Se). than the opac. , .... lIIu. tration 7.28c). Withdraw thtI opmg from the tube, notng wtIich way up tt fits 1_ Inustration). Wrthdraw the damping adjust. rod from InIIide the damper cartrkIgoI - If the damper has sunk Into the fOlk. cltaw ~ oot using a pal, 01 thin-nO$&(! pliers (sea 1Ikn1nllon). Remove the I>oIOIng tool from the

spacer " required. but nota that it ....11 be rI8eded lor Installation. 8 On 1993 1'111 1994 YZF750 R a nd 5P models. two washers are filled belw"", the

bottom 01 tN spring and the top 01 the damper cartridge. It Is unli~tIIy that Ihay will come 001 with the spring. and ~ .. diffK:ult to ratrlevtt them from the fori< with thtI oil stiR In

tt.

When draining Ihe oil

r_ ""X, 5t",,), tRk..

bottom at the Inner tube ,see illus tration}. Oiscacd the 88aUr>g washer as a new one must boo used on ",aasamb'V. Invert thfl Iotk and withdraw Ihe damper cartridge from _ the ,~

11 C8RI/uI'V prtse 001 thtI dust seal from thtI bollom of thtI outer tube 10 gain access to thtI oil seal retaining clip (_ illustration). Discard the dust seal as a new one must be . 12 Careful'll """"". the retanIng clip. taIdng CSfft not to scratch the furl.ce of th .. lube ,_ Illustration).

• 7.10 Unscrew..m remove the damper cartridge bo~

7.11 PriHontiledustHai .

7.12 .•. thfIr\ l _ out the retaining c np using a nat-bladed K rawdriv ...

6- 10 Frame, suspension and final drive

13 To Mj)IW'IIt. !he !mer tube from !he OOIer tube ~ II neeeasary to dlspl8Cf1 the bottom bue.h and 011 M81. The top bush ahould not pus tIYough the bottom bush, WId W. can be uud 10 good effect. Pull'! the Inner tube

IiJ8IIII'I tnw.rdI; until" ~ Take C¥9 ~ 10

do till, Io
. """.

way up they III t_ Dlu,It.llonj . DiIearo the oil seal ..->d the dust seal as MW ...............11

t5 CINn .. pIrtIln ..w.rt ..->d tmw I'*" d!y...tlh comprMHd If lltaIIabII. ChIck the In ..... tube lor mll"kl. K"tChft, !laking of the cnrome IInish and II>Cc:essMI 0< a.bnormII _ . the Inn« tube Tn both

*.

..::0<. "*-

~

"ny dtntl

11""

found. Cheek the fork

seal SIal In the bottom of the outer tube fo<

nleks, llougH and 1C,"ch... 11 d.mllge I, avidenl. IuU will o«:ur. Also check the 011 seal ......."... 10< dl~ 0< d;atO<1ion Ind

_hlf--,.. 14 cn.ck the spring lor craeb IOd o(her ~. u....... m. sprtng free length end

compar. tM m.nur..,.,ent to lhe speciIIcIttlonlll the beglorWlg of the ChapMt. 11 h Is dof&c1l .... or IIOIIed below the ~ limit .•epllca the springs In both lork, with MW or.. NeYer renew only one spMg. t7 Ex ........ the.....:rting ....tac.. of the two buah&s: 11 worn 0< aellNed they mull be

........ad. V...... _0fTIfTIMId MW ~ . . fitted .. I ".,.\1. 01 COU"H. t8 Check the t\Irr4ler certridgIit ~ daonIgIlnd _ , and _ i t . - ylor .

7.208 Slide the dust _I, the ...wlnlnll Clip, the 011 INI, the 011 Mal w•• h ... Ind the bottom bush onto the In ..... lube ..

""'-

til Wnop_losuIating tape t:Ner!he ridgM

on the lop 01 the Inner tube to ptOIect the IipI 01 !he new 01 MIll .. it It 1nstaIed.

InspecUon

lork.

Reassembly

HoldIng the outMSe 01 the t\Irr4ler. purl1fl the rod In WId out oIlha damper. If the rod dOeI not rnovfI amoothty In the dllmp/W k rTIUIt be

rapiaced wtth a new one.

20 Apply a . . - 01 !he tp6CII\ed ciIerIlllfk Oil to !he Ups of the 011 a. .t and lhe In.....

....t_ of e.:h bush. \I*> ..,. !hi new dust __ • !he retaioing clip. !he oIlN1. IhI oil _ waaher and tha bottom bush OI"Ito tlla in ..... tut.., milking ...... thM ~ha marked side of the oil seal 1",-"", the dull __ t_ Illuslt'lionj. Ramo ..... the InsulaU"II tap" and lit tl>e top buah Into Ita _ _ In the lube ( _ MIuWationI. 21 Apply I . , - - 0I1h1 tp6CII\ed cte.. fDI1< Dillo the out. aurlloCI of each bush. tilton carllfully Insert the Inner tube tully Into the

outer tube t_

tau.tretlonl.

22 Support the fDI1< '-'P'Idt down, \I*> prest !he bottom bush IqUlftly ... to its 'I!OIISS ... !he outa. luba as la. II pOlSibift (... lIIultratlonl. SfIda the oil seal waaher on lop of the 00"'. al'd keep tl>e 011 seal. the Ntaining cip lind the dUll! .... 0lII 0I1hI ......., by IlIding them up the In..... tube. If

- V . tape them to the tube to

~

IhIIm from falling down lind Inteo1erIng _ the to.o.h It d'ilted f1to place. 23 Using "ther the apaeial ..-.leI tool (Pt. No. O994O-
Frame, suspension and final drive 6- 11

7.28. Grl", tIM damper cartridge Ind draw II out of thelot1<

7.28 Apply. Ihrud lock ing compound 10 tIM "-mpeor coortrldge boll and ..... new .... InIlWMhet 1M

""11M 01 tIM DuIh.

Mal........ lhe

bus~

_~the_~,...:IlIOkec.enoc

or ~ U. In.- lube. v.t.eo 1M buah II _teod fully and

10 ICnICh ~

~ In I b . - In the tubII ~ the ....... to chick. ~ the . . . . ~ Ihen

";nstall thII wQher). driv. tIM oil ..... inlo pI.c. " ~ in Step 23 un\il 1M rwtainIng gIp gn;llMllI .............. the . . . f_ IIwtrltlon). 25 O""::'lIMoII_II;~_ed,litthe ,..tlln ng clip. making lura II II correctly Ioeoted In III groove. tIW1 po--. the dust _I Into P"*IIon t_ IlIu, tr"lonsj. 28 l...fy 1M lork ~II and puoh \tie !nnw tube tully InlO tM outer tube. 0... 1993 and 11190t YZF750R ...:I SP rnor;leII;, fit 11M side w....... and the Iell wIsIl .. onlO tllfl tOp of tha damt:*" CIfI'idge, w;lh tha ran UflPI<'TIOSI t_ "Iultrallon 7.11. Insen the ~ ...-ukIge Into the top 01 the loti< o.mJ ~ _ on the DOItom 01 the .... tube. Flta new lNIing watt- onto the dam!*, ClrtrlOQe boh and appI)r I r_ <1ropI; of a

w"""_

sultablot

non-""""."..,t

ItviIad

_

lin IimeoI ...:h 10 d~rIbute II -.Iy Ifld

"pel 1111 the .... t- Illustration 7.591). Be carelli not to .~tend the out.. lube trv ~ than 12'0 mm _ pumping II aa thIS coon r;:aI,IM ... 10 ant .. the aystem, In whiCh cu. 1M P'OCftI mUll be ....... ted. W-'! I.., mtnulM. 1herI tully compress the Iot1< Ind - . . the tone oil ....... IR>m the lOp of thII tube !Me -..tratIon 7..5l1b1. Add Of ~ 1or1<.
~

1ISopI ...~0U1 oIN tubo. tMt ..

7.28b TIe I pleca 01 wi.. a~und the ......11« coortridga as shown and "'a II to k...,thecoortrlclgalll_

jMcI crI wire ...-ou"Id the base 01 thelocl
on. an lip on IhI bottom fils into the tOp of the IPrinII t_ "'Irr.tion). Push - . . on the ~ using 1M tool and tnMtt I tuitlbly Ilzed Wllher with I 1101 cut Into II (II uHCI on ~ the lop of the _ Ind

fImO'4III

1M baH 01 the locknut on t"- dlmper CIMdgtr t_ Nlustratlonl. This will keep I~ ___ and spring <:On'IprtI$SId whill; instilling lhe lop boh ueembly. You can now 'tmOVl lhe piece 01wire. 2fI TIYlld tM locknut up t"- dam!*, cartridge 10 that the
t- _1rItIon1·

•

Iocklng

compound. \hen In.lln the boll into 1M bottom of thII In.- lube ..,., IIghIM II to the IOfq .... HllIng apKi1Ied ., the beginning of the Chlpter 1_ Mlu, tratlonl. ~ the daml*' cartfki;;I& t01a1M InIIde lhe lube. wail unlillhe Iotk II fully ,.......b/ed be10re light.....-,g the

...

27 Stand 11M IcrI< upright. $lowly po<>' In the apKltIed quan1lt~ and lItadl of lorI< 011 and pump the IcrI< end ~ ~ slowly at

7 . • FIt the _ I n t o the top of the ~

...

w_ . . .

7.28d , .• thin puSh down on the _ to COIftPrIII the aprInQ Ind In...-t the aIottad wn

6. 12 Frame, suspension and final drive

7.29 Set tM locknut M tM ~ Mpth

7.30 ••• then thnoad tM top bolt a.....,bIy

ontM~ ...

onto II

T.32 ThrMd tM top boil Into tM lorI! 30 Fit a rleW O-ring onto the damping adjust",/pre-ioad adj .... I..ltop bolt assembly and thread it down onto the damper cartr\doII unlilll _IS .In$t the locknut, hokIlng the rod to prevent 11 from turning i_ IIlultrMion). CounI"-hoId the top bolt and lighten the Iodu"tut MCUre/V eg.aInsIlt 10 the specified torque If the correct tools ... IIWiahII! ( _ lIIultrallon 7.8). 3 1 Push down on I,"" IIf)8OIIr USing the tool and have en assistant remove the fabrlcatad slotted washer. then slowly rsIease the spring pres,urI and a llow the spacer to settie I~lnst Ita pre.la.d adjust&!" arms (I •• lllullntlonr; 7..5c ....t b). Ram<:we the holding tool ffom the~. 32 /4f1pjy a ~ of the IPKIIIad ~ oil 10 the Ulp boll <>-mg. f~ PISld the 00Ier tOOe In bolt inlo the IUba

malr.lng .....

11 "

not cfOu-threaded

1_

Illultratlon). Note: The top bolt CIIn be lighlelled to the Ipec/fIad torQUe salting 81 rhIa Slage if the luba II held belWN() the padded J-ws of II vica. 001 do nol rni< diSIM,nt;1 Ilia tube by doInt;1 $0. A bat'-" ,../hod is to 1Igh/wl tlla lop bolt wilen Ilia 101* leg hal ~ Installed ald 18 .:uaty /IeId tithe )'O/uIs.

...

If th ... damper c.rtrldg. Allen boll requl ... Tlgh11t!liflg , clamp 1he fori< between Ihe padded jaws 01 a vIca and hIlv ... an ~t campr_ The IotIt M) thaT muimum spring

7.34 Front fork c:omponen'- - VZF1000R models Forl
"," "" , """""

.--O-mg

, ""'" , ,~

9 Rebound damping edju.~rod 10o.nv:-~.,)(I

rebound $pfiIg " ForlI tube

'2 Bonom bush '3 ForlI profeCto(

'.-OWI"

IS R&rlJlnlllg clip

160i1se111 17Was:J.18 Tep bush '9 Fotf< sIidr 20 ~~ boll .",;j ~ ..........

pre$Sure " placed on the damper canridga I.-f -lighten the bod to the ~ \OrQUI Mttlng I_~ 7..2). 33 Instal the forI
YZF1000R model. Disassembly ~ diatrwllia the fori< legs ~111fy to.void i'teod_ .... ", parbI end thus CIIUIIIng en accaIIIndlld rat. of _ . Slonl" QOrTIPO" nenlS in separate. clearty mIIt1<ed conlalMrl 34

1_ iIIustrallonj

Frame, suspension and final drive 6-13

, 7:n

Unscrew the tDj> bolt !rom the

315 Before

,ort.

""'"

dlsmant~ng the lo
this stage. Turn the 10.1< upside down "",I

compress tho! !IIidoor 00 that the apring

e~~s

mI\Jln'Ium pressure on til
head, Ihfln have an a»lstarot .Iacken the damper cartridge bo!I In the base 01 the IO<'k slider (s. . illustration 7.21. If 8tl assistant is 1>01 available, clamp the brake cal iper mou/1t>-1g lugs ~ the padded laws 01 a \lice to $Uppor! the fori<. 36 If the loti< top bolt was not aIac!<ened with the 1O<'k in aIIu, carefuly clamp lIMo """ luo. In • vice eqUipped with 80ft jaws. takiog care not 10 O\9tighten or SOOf1I Hs surface. 37 Unscrew IhfI loti< top bo/Ilrom the lOP 01 the 10<1< tube (.... Illustratlonj. The bot! w ill ,....,..., tlYeeOed on the damper cartridll". 36 Carefully clamp the fork sl ide' between the padded jIIo_ of .. ...;.;. ""'" slk!e 1tM Iot'I< tube down Into the slider a IflUe w~ (wrap a rag around !he lop oIlhe lube 10 minImi!Ie 011 spillage) while, with the sid 01 In assistant H necessary. keeping the d~ cartridge lull}' ••, _ . CoonI<)r'hoId the pre-load adiust.... 1her1 slack8ll the Iod
7.39lI Compr4lU the for1< tube and W"\1tIdrlow the damper cartridge to e _ the cir<:lip I_edl . tllat tha circl ip i. _xposed I... Illustration) . I(.... p the damper cartridge e xtended ""Ih the lid olin assiSI"nt. then r8nlOWI the cirdip lseeillustratlon)

80

7.39b .•• then remo .... the clrcllp, using • ~ o l _ . s ahown to prevent It laUlnginto the fort< carl1idoe boil and

~s

copper sealing wasl>er

from the boltom of 'he slider tsae illustration 7. 10). Discard the sealing wastNlr as. ~ one must be used on reassembly. 43 Invert the 'one and 'Nill>d
(n. iIIustraUon). Now CDunlet-nold the ""'knut and thread the top bolt 1ISSWIlb/y a ll the oarnpow cartridll". IMn thrMd the kx:krlul ott the rod. ~ the adjuster rod from the

40 Remove Ihe col lar and the s pacer and

centre of the dampe< cartridge ( _ iIIuslnltlonj. 39 SI>da Ihe fork tube lully down Into tll
and I'\'mp the 1011< lind lhe damper cartridge vigorously 10 expel as much fori< oil as

7.40 Removto the eoNa, !Allnd space< (tI), then withdrlIw the spring Ie)

7.43 WIthdr.... the damper cartridge

withdraw the .pring from lhe lube. noti ng which way up ~ M. lsee Hlustrallon) . 41 _ the Io
-~

42 Remove the previously slackened damper

44 C8re1"'tv prise out the dusl seal from the top of the sUder to gain access to the 0/1 seal retaining clip ts.. Hlust,.llon). Discard the dust seat as a ne ... one must be used. Note that the IOI"k protecl Of should oot be ren'I<MId from the top 01 the slid .... unless "",,"sary, and WH .. ren'I<MId, H should be replaced with

"new 0IlfI.

45 GareMy retI'"oOVe the fetairling clip. taking care not 10 scralch the surface of Ihe lube lsee illustration). 46 To separate the lube from the slider II is

necessary to displace the lop bush and 011

7.44 Prise off the dUSI .....

6- 14 Frame, suspension and final drive

Mal. TM botlom bu,h t/IO<Jld ""' pall ttwough the lop bush, lrod Ihis can be used 10 good . flecl. Push Ihe lUbe genlly In ...... rda un ll l II IIOPS .glinsl Ille d.mper c.nrldge _ . T.k. cars "'" 10 do ttl'- lorcibly or tile

...t .... y be d.~. Th.., pull tile tube .r..pi)I outwartb untj Iht bottom bush s\riI(M tht lOp bus/\. ~ this operation untl tht lOp buIIIlWld seal are bpped out of tile slider (_I.ullration1,131. 11 Wilh Ihe tube removed, ,lIde ofl tha all Mal, wS$Iw" and lop buill. noting which ..... IIy up""-y IiI (sea Ilfultrllllon). Discard the 011 ...... a ....... one must be UMd. esullon: Do nol _VII 1M botlom bush from ",. lliba un/eu If Is to be ~,

Inspection 48 Clean an parts In solvent and blow Ihem dry ..... ~h compres.ed .Ir. II available. C~k Ille lork tube lor Kars marl<.s, scratch", n.kIng of the chrome fInIIh and excessive 01' .tInormaI _ . Look lor dents In the tube IWld rapIKe the tube in bolt! Io!b with ....... ~ ~

any are fOUnd . Chaclt Ille lor!< pal . . .t tor nick •• gouges and sc::retchM. II damage I,

rrid...,t. leaks ..... ill occur. Also check the 011 seal ..... asher lor d.mage or distortion and ~ ~ with a new one If nece!I!IafY. 18 Check the lark tube for runout (bandIng) u.lng V-bIocks.nd • dis! gauge, or heve II done by • Yamaha dH_ or suapenalon specIaIisl 1_ Ylustrlltlon 1,16). Yamaha do not IIPICIfV a runouIlImfI. buI If the tube is t.>I beyond the II'fWIIIy lOC(:fIpIed limit &pecl!Ied, It stlOUld be replaced with a new one.

Warning:" tlla lube /. INnl, If .hould nOI be ,'re/glll.nad; repI.ca It with. ,...... ona.

.& , •

50 Check Ille spring lor crack••nd other ~. Meau.. the spring fr_langlh IWld compare 1M measuremenl 10 1111 spKificatIons III the beginning altha Chapter. If It is defectl've 01' sagged below the ..w:. limit. replace 1M IpringS in bolh foOIl with new or.. ~ rapIae
~"""'.

lil Examine 1M WOIIIing Mace. of the IWO bushel; II worn or acuffed they mUlt be -.p/aCftd with _ ones. To remove tile bottom bush from lilt foOl tuba, prise II apw\

at the alit tI8ing a lIa1·bIadId set'IWCIImr 8I'Id ,'lde It 1_ IIlullr.tlon). Make lUre the _ one seats prOperly.

0"

52 Check tile darn!*, Clll'lriOge .-rtbly 101' damage and _ , and replace II with a_

one II oeceasary. HoId'ng lhe outside 011111 damper. pump 1111 rod in and out 01 the

-.

darrI!:*." the rod 00. not move....oothly In Ihe damper It mull be repIsc:ed wll/\ • new Reassembly 53 Insert the damper cartridge InlO the forlo: tuba and slOe ~ InIO pIooe !IO !hal ~ projects fully from the bollom of tlla lUbe ( _ llfuatration 1.13) 51 01 the ron. lube and bottom bush wilt! the apac:I!Ied fork 01 and n..t the as..nbIy Into Iha slider ( _ lIIutlrstlon) . Maka IUr. lhat Ihe bollom 01 the damper cartridge ~ales

correctly Into 1111 bollom 01 tM Illder, otherwise the damper cartridge

ADen bolt wil

nOI Ihread Inlo Ihl! rod. Look up Into the bollom 01 lhe fori< via the bolt /\ole 10 check. Fit a new copper sealing onto the dam!*, ~ bolt and ~. lew drops 01 • IUltabla ",,"-permanent liIre8d locking compound, lIMn Install 1111 bolt into the bollom 011111 "ider (s_ lIIuII..llon 1.2ti). TIghten Ih. boll 10 the .peeilled lorque setting. Illhe damper cartridge rot8l .. iMIde Ihe lube, wall until Ihe Iorio: I. fully reassembled before tighI~ the bolt. 55 Push till foOl lube fully Into the "icier, then 011 the lOP bush and aIIda 1\ down 0-.. the lube (sea illultr.tlon) . Pr_ Ihe bush 8Iquarely Into ~I recess In the IIdoIr as lar as pOSSible, then Install tn.. 011 seal washer wilh ~s flat side lacing up (see ilfullr.,lon). E~her tJ.StI 1M V.maha service 1001 or a aullable piece allubing 10 tap the bush fully Into place; \he \Ut:IIng musl be slighdy '-tIIr In dIaonetRr Ulan the fork tube and allgl'llly tmaller In diarnel.. than the bush _ l i n the slide<. Take car. not 10 IICrlIlch the ron. lube during thIS cpon!lon; It is best 10 mak ....... thai the fork \ubi is pUshed lulfy InIO lhe slider 10 that any ICCldlnlalacr.lching Is conflned to the ......1Ibova the oil Mal. 515 When the bush Is fully and ~ In Its raceu In the IIfder (ra'noYe the

w.""'"

_,ed

washer 10 ched<, wipe the receu cNl, then relnstal the washer), Instau 1111 _ oIt Mal. Smear Iha Hll's lips ..... I,h lithlum·blsed

grease Ind , 'Ide

~

over Ihe tube 10 Ihal

~s

Frame, suspension and final drive 6-1 5

7.511 Maka ...... the oU _

I li the COfTeC1

1.118 ... loIlowedbythedutt _l..

1.51 InttaU the "Ialrllrlg cNp.

""yup I'r\IIrkIrogI. . _ upwIrdS and drive \tie . . . into place . . ~ _ un!llthe I'1IIainIng cUp grocmo II vbllM above ,"- _I 1_

..........

~_oIdoll_..,,1Gp

~ -. 57

to profKt /I

•

of the ..... _

I

""'"" driving fhe ...J info

o.-.c.,,,- -' II corrKlIy Malecl. iii 1"-

.-.ta,.,'ng c lip. maklnQ 'u,a It ;. correctly kx:atld In ~. QrOOYI I_ n,,,,,uation). sa Lubf~l. thl IIP10 01 ,"- new dus ...., then .,Ide ~ down t"- tori< tube and press ~ into poeItlon I_ nkJ.tratlon). 50 Slowly pou- In thoo ~ quanllly and grada 01 lone 011. ,...... pump ,"- damper cartridge lira!. tt-..n !hi fOIi< tut... at least t..,

1._

Pour_oil Into_lop of_lube

•

1.Il0l> ..• ~by_~ ....

..,..,Iy

t"'- NC:~ '0 dlll"I>\Itl the 011 and /'IIIIOVI ..-y ... ' - - 1_ 1IIustretIon). Be c.weIuI not to P lend the lube by more than '30 mm ...... PImpor!Q 11_ 1IW cal cao.. ... to ent... t"- 'yalem. I., which caM tM

mnn...

~ ........ ~ ~11d. Wart t.., then 1liiy ~ the toot< lube ..-.c:I cIa/TlJ*' CIftridge Into the IIIIdII' ..-.c:I . . - It.- fOIi< 011 ....... from the top 01 the lube 1_ ......u.tIon). Add 01 toJblraCt folk 01 ""III II II II ,"- ...... tpeClnld at the beginrllng 01 the c:t\.Ipl ... .

110 Clamp 1"- ,lIdtIr I., a vice via 1"- brakl clilper ITIO\In!lng lug •• taking certl no. 10 ov .... lgll' ...... nd damaga tllem. Pull 11>1 lor\< lu~ IIIld cIImper cartridge out 01 tile slider .. ~ tile spmg witIIlb lape'Iod end at the top 1_ lIhI.tration). f"~

......

"*' .....,..

tile _ _• with Its IapeNd ond

--

fiImo

into the

7.5Ob M.._.theoll _ _ _ .......

.....

"*'

lop 01 Ille 1Pf1tl\I. fit the ooIIr Into the top 01 the _ _ _ ....tmionaj. • pieCe 01 paper .,ound the damper cartridge . . on F'~

mov.). "*'

cIiIeeMmbIy 1_ Kayne$ Hinl ftt the Cin:IIp. maklr>g ItQ II kx:at .. oorrectIy

In,o it, gr........ 1_ Inultration) F'~ tM d .... pIng Idj ....t... rod Irno the damper cer1!'IdQlII_ ......"..,.,., 7.38b). 11 T~,ead tile Iockn'" onto the daml*' cartrIcIge..-.c:l lei II., that Ihfn is 16 mm 01 dampef cartri~a thread a bov1o It 1_ lIIu.lratlon.). Fil , new a-ring 011'0 the 10<1\ top bOjl. TII,Md tile top bolt a ..embly onto Iha d.mpef cart"dgll unlil II conlact. tile Iocknu', then count ...· hold tllll prl''''''d ad)u.'", ,.,d Ilghl&n till Iockoul .K... IOgIIfItIIi 1_ lllutu.tlon and 1.3811) . e2 Wi01chwthetubelulylnlmtt. .... ..-.c:I C""".y _ 1he lop bQIt into 1he iorio: tut..

,.1y

7 __ Inttall the spring .

•

6-16 Frame, suspension and final drive

8 Steering Itemremoval and installallon

.. ~

Removal I Remove the

'**' u..

I~j(jng

ar>d the lairlng aide

(a. Chepter 6). It • .-0 ~ to ......ave lull tenk 10 IIVOId !he possIbIIrty 01

7.811 Tlvud the locknut onto the dMIper ~

...

--

7.alb ••• ...ct ..IIt.ltheC<>n'eCtpoaition

7.151c n.,...d the top bolt assembly onlo the damper cartridge MIl 11$hI... It agal".1

......""'"

mPing __ ~ 10; not o;fW'-~ 1_ IlhJltnt:lon). Note: The rop bolt eat! 0. I/ghMMd 10 Ihe specified torque sertklg .1 /his ar.g. if the ~ is held 0 . _ the1»dd«J Jews "" • ..ro., but do not . . GIfsIorboIg ftIe lube

by daIng..a. A be!tr ,.,.!hod Is to f9'>ren !>'Ie top t:IOIf wfMn the forl< ~ has bHn in5flJi!e<1 If>d Is MCU/'lIoY haId" !he " . . ~ •

.p Y. ~

lJMa ..tcn.t·~loot ...,.." Insl.lllnrl th_ fo,* fOP bolt. This m.lrHItUrlrIIONAlY 10 remo~. th. tool Ih. boll ""'ilIt tt>rettrIJng It In.

',.om

u..

II damper cartndgl Allen bolt raqu" .. lightlll"ling. clamp the Iork slider ~ !he pad<Md jaws 01 . VIciI and have an USlSlant com pre.. the Il,IbI Into tha s lid&!" Ml t hat

r.

8.3

DI~

u.. .........oIr(eI !rom u.. top p • ...

.cnotchlng It 1_ ~.) 2 Remove Ihe lront Iorks 1_ Sectloll 6). 3 Unscr_ the boll eecurlrlg the /root bnlke mut ... cyfinder , .....010" brecI<et. and on VZF750R end SP modeIII, the dutch _ _ _ brKket. to the lOP yoka , _ ",u atra llonl I(Mp the .-voIrja) uprighl • [)jsconMd the !"10m wiring connector.. then unser_ lhe bolta MeUMIi u.. Id remove the locknut ...mg ..tnar a C'_Mel". a pag _nnet" or • dnft IocIta
rubber washer (_ Ntustratlonl 8 SupPOrtIng the bottom yoke. unscrew the adjl&ter nut UIing ..!her. C-IIf*"O"W". a PIlI" -"'* or I dnIt located In one 01 lhe ~ ~ remove Ihe adf
maxlmum &pring pr ..... is plKad on the damper cartridge heM! - tighllln Ihe damper cartridge Allan bott 10 Ihi specI/led torque setting ( _ illulll.uon 7..21. 83 Inltall the 10000s (... Sectioo 8). Sal th_ sprIng pra.load and damping adjusters as ~ " " Section 12).

IUtKtrationa) II Gandy lower the bottom yoke .-.d ataerW1g stem 0lII oIl1le trarne (HI ....tration)

8.111 Unacrew u.. II-mg stam nul

8.1b ... and 1111 u.. yoIIl up orr u..

!In'Dwed) •.•

---

Frame, suspension and final drive 6-17

10 ~!he""""f_and~ lfOfTl the 109 01 !he 1IMf1"11 head 1_ InU''''"tJonl 1.12b Ind el. Remov. the WMIw. t.e.ing end n.t.ber dust _ trom !he ~ 01 the 1_

.,..;ng

.t....

lIIu " •• t1on. l . llC, b . nd .1. Remove ell !fee" 01 old g _ from IIMt bearings and _ Irld c:t>eck lhem lot _ or dan'IlIge •

dMC:ribed In s.ctIon g. Note: Do nol IIIWIl>/ 10 _ / h e _ hom /he "-dor

-ww

tIM .tHrlng ""'" un/e$$ they .,. 10 ~with_ ......

e..

In.tallaf/on 11

s..-. IiberaoI ~ of &thIum-baMd

g _ onlO !he bearing

r8Cel. Alto wOtI\ gtNM Inlo both IIMt upper and lower tlMrIngs. fII the n.t.ber dust . . . _ !he _ bNring Inner rae:. on !he IIe.1ng

w"

- .. _

.t..,. tt.. fit

the~ roc!

thew ....... 1_

12 Cwefully litt the I t-;"II .,emibonom yoke up Ihrough tile 81een"ll held ( _

Mlwllretion I.a) . F~ the upper ~ Irld the ~ ......_ Into lhe top olth .. s l...tng htt6d. Ihen Inlll il Ihe bearing co_ (_ IIlu,'r,lIon. Ind 1.8bI. Thread the adJuSI'" nut onto lhe tleer>ng stem and Idlu" the ~.rI"O' II dHcribeCI In Chlpl.. 1 (_ IIIuItr'.uon &.all.

&.lIC

:•

i~!i~ m~w ~, o n,.~.!'

~.,-!t i l ~

t

mH '_ ,

m,~i, --'~-~ik1/, ii H

.. ~

ii ~:

~l

.

~ :~

~

'~

_ !I

~i

'Ig.

~; a~ ~~~

't~il ~~-

Uh %i

.

l~~~~i[

~.gi!

H~ !(~[

~lifl Ii,\!!

H " ~" " iHHH P .~t 1

i

l

h tmi~H mH [J~ ~ .. ~! l~ir*i'Ii'!''' ! -::r:&

~~~~i ~~s.~a. g; ~ 1

;o;!; -

li i~KglijS"' i .i5:i

;i=

2.o1 .._It !: .&'· ;;ti~s~ ..

~g~

(t!!

H ~;' g~J.~H Hi~ ~ 3'

-~

i!

~-5~q. -I" .£ "

-

m

H(iihhHlm m

"2."

~~ ~io~ ~'~l~~li~ sli

1'111tJ

HHtilUW 'iHpF 11 I!I mum [! mmi riHmm " ;i"·" I..H."/:

1~'!;!~,!

i~ii'!e=~i ~ -

"~"n.~l'~'

~~~iil;i 'il ~

!~I' ~;.

~, ~"!e~~-::r~ !.. -~~lil~"~j

iii! i ~~~~lil ,~:~~~~ iil~[f!~; ~! l~iii·l I![i~~!ilj .=,j ~ 'o'''.il •• :~ f .i _of'lt 'i !o,~O" 1"·I'!i

I !ii~~!!iij!

;!i;;;

iii

§

Sl~ii"~~

8.2-~

-~•

!r~~[~l

3"ll! Z ~

'H;~ ~~i ~ ~<;..

a. !.

~

~

j"'~E ii;~[i~~~!~ ~ ~

H gco

~

hH! ~.;s~5'~ :S. ~~

S'le

~. ~:... alH ... ~~ ""'1

-,

lli[~g:' OI i

~

iilQ.il

~ I ,. ~-, .

a·og.:f5. = ~

F!~~[ ; f ~

;~~g~~~~ ~

;1

1/;: Jj

" f

"

!

~ ,~g.,. .. HLo

~;~!J~~! ~I l!itI~1 !~i~!i' . i

i~li!ili!li! !i!~!i 111;111 ,. ;1!11! {i!Ji!~ii i i~ ~! ~; l~l[jl~;l

'--_____---' ~il~-!~~_i[l~i J$~~~~ ~§ ili~I

..g ~

[ ~

~.

Frame, suspension and final drive 6- 19

11.8

~

....... w '.c:_ on usln\l • aultabl
drIYw Go' •

*'11th 01 ""'"

e Fit \ht' new tow.r r.c:l onto \ht' ste.1rlg .tem. A ling!" 01 lubing with an Intlmll ~ aIghtIy IIrgIr tIwI tt. st..r.g s1em

wi.

bot MIded I<) IIIP !hi poMIon ~ . . .1rItlon1

new

race into

, InIUIIIIhe llIftIg Item (MI Section 81.

10 Rear shock ebsotbef removal , Inspection and Installation

A ill

t. "

~

Wlrn/n,,: 00 not attempt to

<11. ., ..... _ th!. shock .9bIorbII". If II n/t~""'~ undlo'''/tIII p .... I1. .. ImprO,..r dlu ......b/r C<»I/d ..s ull In IMIouI Injury. In l feMI, ti ki thl shock to I Y..".h.. diller or , uSplnsion apocIINst to do 1M job.

•

to.&o Un.c_ .... nuI..-..I.....-.o ....... upper mounllng bolt •

withdraw !hi bolt IICUriog the IinkIg& rodI!o

Remove' 1 Support tlMo molorcycHo HCUnIty in IlIl

upright pos.lion UIIng an IUdiary .tIOd PoIibon IIIJPPOI\ ...... Ihe . . . wheel .. 1hII ~ Ihe ahod< ~ II ..-no¥Id. bo.II ~ 1hII1he WII9II 0I1he II 011 ....... ~ .. thIt the shock II not~. 2 R _ .......,. aide covers or ...1 oowIh;J. WId Ic:>w.- lairing (_ Chap\.- 8). _ the lUll bonk t- Chapter ~). 3 Removl lIMo battery (see Chapter 9). On YZFt OOOR modIiI. disconnect !hi starter reiay wiring connector then disp1lcl the relay /rom 111 IllOUIIt t_ Mlu.lrillon). Unscrew !hi two boll. lICurIog the baltery box 1_

b 00II not drop

"*"*"*'

....

1IuItratIor\I. SoIIc:MIIhi cItImp iK>"eW ~ lIMo ,...,go to ~ IlDkIIr ISM 1IIuItrMIonI. ~

Ut\IcrIW tlMo nut, .......a.... ........... WId

10.5b •.• thin Iowltlhl ehock.

lIMo ~ ISM 1III.*I1rItlon1. ~ the nut. _ Ihe WISIw" .-xl withdraw Ihe boll IICUriog !hi boI1om 01 the shoCk ~ 10 lIMo Ir'bQI a'ITl, then IwWIg !hi rods .-xl !hi a'ITl down 10 prOVide ~ lor Ihe shock ~ 1IuItraIIonJ. On YZF750SP modIIa, Il0l1 Ihe coIIrIltwIt fi1 ' * - ' the ahoCk ..,.;I1he ."" Ind
.,_.

5 lJnIM:rlW tlMo nut on the shock absorbet UPIlIt mountIng bOlt. ti>otr'l support thto shock Ibsorblr Ir.d wlthdr. w the bolt t_ Wlustrltlon). UtI tile swinll""" and lower tile iU\OC:k out 01 11M 1rarM. leeding l hto ~ down b I t _ the upper mudgotlrd ....,;I the frame, taIdng ..... IlOl to ocratch eroything - H101 . - y 10 puIh the mudguard In to prooAde ciNrWIce . ..,.;I _ thin 11 loll tight lit t_ INu I V..uon.J The.rt.....- 10 Ihe _

to.lie • .. r..dlng the......-volr between the fnome lind the batt«y bo_ •. .

6- 20 Frame, suspension and final drive

10.7 LooI< lor cnc:l
_

upper muclguwd, _

d'....

~

itI bolla and

beck 01111>8 meeI\ir1e to provide Ihto

cIeanIncoo Ior!he.-volr.

Inspection , lnapooct the ,hock . _ !of obY\oIA; phyaIcaI demege Mel !he coil tpMg 10< ~ crecIIs or.q.oI ~ 7 Inspect me ~ rod Ior.,;g,. 01 DendIng. pot1ioo In:I 01 . . . INa iIkmmionI 8 Inspect _ p/vo1 h...dware al the lop and bottom 01 ll>e1ltK>ck for ... ear or demege.

Ingg.

..

Ihoc:k low ... bolt IAI, _ ....,.·1........ bolt (8), _ _

11.3 Remove _

-.g. .....,0-"'- bolt ICI, M e I _ ~

o Check the ' ....... 0;'. hose end hose COfWIeCIlonIlor demege, creeks or ~. 10 IndMd .... cornpo!*lts .... not ...... bIa lor Iha ahock ebaofb«. II It 110 worn Of "-nIIged. _ rnuat be .-.placed with ............

10. 11

--

TtocIh*> It.. _

to IhI ~

Instal/llt/on

11 In".n'tlon Is the ,IIY_ 01 ,,"''''val. App/\I ~um dl.."phide iI'.... 10 the $hock abaorIJar and rod pivot points lostall the bo/tf lind nuts /IngoIr.tlght only l>'ltiI all .... .,senIrogIlpacII\ad P'*IIon, I'*' tlghtan _ ~I' to _ ., the

'''kage

~

from IhI bottom

~

10.5
tJagirri'>g 01 _

ChIpIerl_ .....tratlon).

11 Rearsuspensionllnkage removal. Inspection and installation

~

'!iO.: ~

Remo""' 1 Support It.. molOtCyCla MCU...., MI an upright positIOn using en .udlary stand.

Position. tupport under the ...1 wheel so Ihet It doa& not drop wi*> the ahOdc abeorber low&l' mounting bolt I, ramov~, but .Iso making ..... Ihet !he weight 01 !he macNoa is 011 It.. _ IoUSpans;on 10 INII It.. shock Is 2~-. Rtorno-.. tM Mal. aide fairIng!-CMpI-8j. 3

C:OV... _

lower

l./r«:feW_~."""""'_wuherland

INIthd'.... the bolts Heuring 1M shock absorber and 1M linkage rod, 10 It.. linkage ann (... IIl u,tratlon). NO,. ....mieh bolts IiI - . . On VV'75OSP rnodIiI. note !he colin IhaII m ~ It.. IIhock and tl>8 .... and ....,..,..,1t1am b AIakeeping II raqo.Qd. 4 lJnKraw tha nul, .......... It.. wQher _ _ _ _ boll

...,;umg _1Inkega rodsl<J

the lINIngI'm Ind remove the rodI 1_ UluoJlrallorll0.... '. 5 UnlC'.'" tha nut and ... ~hd"... bolt HeU~ng the IInkag. arm to lhe trarM 100 ....,..., .... the lIok11ga arrn. nolong ....mich way roo.nd M1IIs!Ma 11.31.

-.-..1Ion

InSPfICtlon , Wrthdraw ell _ Spacara !rom It.. Nnkage arm and lwingwm, noting IhW dm.rant ell.. ( _ IlluaIr8llon.,. Lev8r the or- _Is out 01 the IInklgl arm. Thoroughly d . ." all C<>rnl>Ol*ltl. ramov\ng aJl

11." Suf,pan-'on -.ge eornpotIDtItS /..inIa(Ja1Odlt /..inIa(Ja....

3 ~

~

4

~

a..a.._

~

or drn.

com>aIon.-.:l W-. 7 inIpect .. ~ cIoaaIy. ~ tor obYIoo.It tIIgr-. of _ suo::h • hIavy KGrfng.

or ro<

~

such as crlCki or dr.tomon.

Frame, suspension and final drive 6- 21 indicalOO by the number 01 crlCk!l w1"MIn tumad anti-clockwise from the fully a<;rswad·ln posltlon, Th .... a .... twelve posliions 00 VZF750R and 51' models, &evanteen 00 1996 and 1997 YZFlOOOR models, and twenty-f"" on IlJ98-.on models. The standard position Is four or Ii .... (yZF750R mod
Slip " Deh spac ... ba<;k InlO lIS beari~ and ~k IhAl tI>ere ill not an "xcesslve amounl 01 Ifeeplay between th" Iwo compon"nlS. Renew any componenls as required. 8 Check Ih" condllioo 01 th" n.....::llft roll ... _ngs in th" IInkagol arm and In !he bottom 01 the swingaml. ReIer 10 Too/$$IId Worl<&'>op np. (Section 5) In tile Ref&reoce section for more Inl00'll81ion 00 bearings. If the IinkaQII rod bearings In th" sWingarm n.....::l 10 be reMwed. remov" thfl .wlngarm ( _

_ a: Refw to /ha ow"",," f>IIndbocJ#I wppiiad wlJ1t /ha macIIInoo for ;dad from and , . . suspens/oll stIlinO'! to suillo9ding.

Section 13). \I Worn bearinOS

Front forlcs

can be drifted out 01 thei' bo..... but not" that 'emoval will d"stroy Ihem: Mw bearings should be obtained before work commences. The new bearing! should be prll$$ed or drawn Inlo Ihei' bores rath ... Ihan driven Into posllioo. In the absence 01 a press. a w~abl " drawboll toot can be mada up ~~ dKCribad In Tool~ and WorIrshcp n,n (Sacllon 5) In tha Reference ~

..

10 lubftcate Ihe needle roller bearings and the spacer1l with molybdenum d isulphide

grease and install the ~. 11 Check the condition of the or88M_ilI for Ih" shock absorber mountino In Ihe Iinkaoa arm and ,_w Ihem H Ihey a,e damaged or deterloraled. Press Iha seals squareiy Into piace.

Installation 12 Installation ill th" ...... e<se 01 removal. Apply molybdenum disulphide to Iha pivot poinlll. ins,,"1 the bolts and nuts linger. tight only until an components ere .., posiIlorl.

0'"''''''

than lighten Ihe nuts to the torqua settings

12 Suspensionadjustments

'..:
I On 1993 YZF750A mod"ls. the fork. ar" ad,ustabl" lor sp!1nO pre·load. On all oth ... modal., th" I.ont lorks a .... a djustabl" lor spring p.e·load. rebound damping. and eomP'M$lorl damping. 2 Spring _load is adjusted using 8 suitable ~ 011 IhIt ",jlusTer !\lit.,. ro the top d Till! forks (H e Iflual.-tion). The amount 01 preload is Indicatad by 1"- on the adjuster. On YZF150R and SP models, there ore eight __ . On 1996 and 1997 YZF1000R tn<>dn YZFlOOOR ITlOOeIs there are fto.re. The SIBtIdard position Is with tha 4th (yZF750R models) or 6th (yZF750SP models) or 3rd (1996 and 1997 YZF1000R mod"ls) or 4th (I99S·oo YZF1000R models) liMjost vis;bIe _ I h e top bolt hex. Tum !he ad;ust... clockwise to Inc'ease pre-load and an:l-cloc kwise 10 decrease ". Always make sure both adjusl8tll are S8l aqudy. 3 R"bound damping l!I adjusted u~lng 8 screwdriver In the 5101 In Iha adjust .... protruding from the p ..... load adjU1it(M" (... lIIu st •• tlon). The amount of damping i,

Tum

u.. adjuot_<:IocI<wiM

to Incr"ase damping and anti-clOCkwise \0 deere",,", It. To .... Iablish the cu,renl setting. tum the adjuster in (clockwise) until it Slops, counting tha fII/ITlOOr of c:IicI<s. than .....t ~ as ,..,qulred by turning H 001. Aiways mak" SUre both adjusters are set~. 4 Compres$lOn damping Is adjusted using a !lCfawd!iver In the slot in the adjutter on lhe base 01 e,ch fori< (... Illustration), The amount of dam!:in!I is Irdcatad by the number 01 _ .....non turned antl-docl<wise from the fully screwed·1n peeition, Thera are ten pos/II<>ns on YZF750R and 51' toodeIa. twentyone on 1996 and 1997 YZFlOOOR moOeIs. and \Wenty- 1tYe on 1996-on models. The stwIdard peeitlon Is se.an (yZF750R models). six (yZF75OSP mod ... ) or lWei"" (yZF1000A models) clicks oJ!, To.rn theadjust .... cIocI<wIse to Increase damp'ng and antl-clockwTM to decraase". To .... tabllsh the currenl setting, tum the adjuster ... (clockwlsa) until ~ stops. C«O'Iting the number of cllcl<s, t,*, _ _ " as requited by tuming It out. AlwaY" make wra both oojusters ara:set equally.

Rear shock absorber 5 On 1993 YZF750R models Ih" rut shock .bsorber Is adjustable lor spring pre-Ioad and 'ebound damping. On all oth ... mod"ls Ilia rear shock abso!'ber Is adjustable for spri~ pre-Ioad, rebound damping and compt8SSion damping.

YZF150R modelS - $pring pre-load 8 On 1993 and UK 1994 YZF750R model,. pr....1oad adjustment is made using a suitable C-spanner (one Is providad In the looIk~) to tum the spring seat on !tie top of the ~hock

absorber (see MluSlretion 12 . 1 ~)_ Thera ..... seven pos~lon., po.moo 1 Is th" softest _'ng. posiIion 3 Is the standard. positiOn 7 is the hardest. Align !he !WIlting required with the adjustment stopper.

6

12.2

S9rir>II _load adjuster (arrowed)

12.3 Aebound dlHnplng adjuster (arrowed)

.

12.4 ComprHsion damping adjust ...

...-

6- 22 Frame, suspension and final drive tbtortIar body. SIecI<en the 1oeIckwisa to Increase prtI10ld and tntl-clockwlse to d.e ..... II Is_ IliuStr8lion 12.11 Togh1 .... thllocknut securely 1ft... ad)U",.,..,I. Me .. sure !hi dLSlance ~

the top of !hi sprtng and tM middIt

01 lro. u~ mounllng \:>I;:Q. The mInimum _ II wttIl t spring length 0115.5 mm. the s landard amount WIth 55.5 mm. and lhe

tum_ rnoo:I*_"

maximum amount with 35.S mm. t .. On 19115-00 YZF750$P mod~ •. s Pling pno·1oad Is IIdjuated by tummg 1M ~ng on thI remota adjusl .... Tum lhe IdjU11 ... In to

12.7 sa.cken _locknut W _

ncr- po-.-Ioad. and t...-n 11 out 10 '*"-

7 Or! us 1994 Y2F75OR 11195on YZF750A modell, ~g prtI·1oad I, adjusted by lurnlng lha adlust .... n~t on tha ttvuds of the shock I~ body. SI&el<en the locknut, th ... tum the actj~st ... nut clockwise to incr_ pt.-load and antlclockwlH to <Meta... It 1_ lilultrtllon)

lVtt... tt. locknut -....y .ner adlo*nWrt.

MMan tt. diMwao bet--. tt. lOp 01 tt. II!)ring In! the rnIddIoI 01 tt. Uppllf mourJlIng bora to obtaln the amount 01 prtI-Ioad MI. The

minimum amount I, with a distance 01 51.5 mm. the atanoard amount with 55.5 mm, In! the """""""' 8rl"IOI.W"It with 61 .5 mm. YZF750R mod .., - rebound damping IS On 19113 and 11M1-1 VZF75Of1 rno<:\W, ~ damping adjustmtnt it made by turning the ed/u"er on the bottom 01 tile shO(:k Ibsorbaf Isaa IIIUlltallon). Tum tha adjuster an~ -cklckwIM (M you i0oi< dOwn lit II from the top) to Incruse damping and clockwiM 10 d-cr_ II. To 85tatlhsh the cu".....t Mlling tum the adjuSI ... anti·

eIockwIIe ~~ It stoPI, ()()plmg IIw ~ 01 dicks. then . - h .. r8QI.ftd by tOOlftg 11 001.

n..... ~ ....... ~ions.. The standIrd

JIOIIbon is nine dieka out. The 1\arOes1 is thrM clicks out. and IN 11011l1li .. eleven click' out. 8 On all other UK VZF750A ~, rebound d~ng

edjustmtont it made by Iurnlng the .quau.· on the bortom 01 tt. Ihock _ _

adjust.-..m-

1_ ~ I 2.IJ TI.W!I the cIoc:I<w*I (as you look down III ~ from the top) to IncrHsa dampong and clockw.M to decr_ it. To -.taDIllIltNt current IIIItong.

tum the &djusler anli·cIockwise un," 11

,,~,

n..... _ ,........ l1li1"'01 .. indicated on thI body of 11\01 adjusl •. The minimum II 0, the ~ 3 In! tt. ~.-deSI12. 00001 I...... the Id)ul1... btyood the mInimum or

II.

Mljust.. {8)" ~

oounting !hi ~ 01 dicks. then . - 11 .. required by lummg It OUI. Thtort ..a twenty

posi1ions. The standard position ;. ten cIiclOCk 1_ ~lustntlon 12.1) Tum the adjuster _ 11 wi Iso (as you i0oi< down .t II from 1M top) 10 Increase damping and clockwisa to d-croall II. To establl,1I tha CU l1"ent SIlti ng, IlJm the adjust ... antl-

""*'"*

"""'**

cIockwiM until h llOpS. courrung the 01 dicks. then.- ~ as .-quQd by "'"*'0 11 out. \NIt.., pOIIItIOna. The lta"IdIrd poaitIon II len dicQ out. The hIrdeat II one c:Id< out. and IIw IIOItest 1111*1_ cIcka out.

n..... ....

YZF750R models - compte.alon damping 11 Compreaslon damping adjultmant it mada by turning tt.. adjust ... on till $hock abeorber -..w 1_ illuslratlonl T...-n the adjust. doekwlSe 10 ~ ~ and ent!-dockwise 10 ~ It. To IMabIiah 11\01 cu-rant MItIng, tun the a::IjUSl'" In fcIocio<'MM) unlll h 11~. counting the number of clicks. then reset 11 _ '«IU1r«! by turning II aut. 12 Thar"e.,. ........ty pos.ltlons. The standard ~ion ill ten clicks out. The IIInIaIIt II one cIcI< aut. and the aoIIe1ll1 twenty <;Icka out. VZF750SP models - apri~ ~-1oiKI t3 On 1993 and '994 YZF750SP modaIs. apring pt.-load I. adjustfl(! by Mnlng tlla adjuster nul on ltoa I~reads on the shock

maximum M1tlngs.

VZF750SP models - reboYnd damping I S 00 1993 and 1994 YZF7SOSP modaIs. rebound damping sdJuslmtlnl II ...- by lurning lhe adJUSI ... on lhe bottom 01 Iha shock at..ort.r 1_ lH",tratlon 12.1). TI.W!I 11\01 ad!uIl. anti-dockwlsa (.. you look down at It from tro. top) 10 Inc"... damping end clockwiH 10 dec ..a .... It. To ..tabllsh tht curranl IIIItlng. tum tha IIdJ~I1" antlcIoci<wIIII until h stopa, COIXl\Ing thI numo... 01 cticIen _11_ r8QI.ftd by Il.rning II out. Ther-. .... IIWI_ ~ The-...ro posihon II ...... dicb out. The hIrdeIIt II one cIcI< out. and IIw softest il1I*I_ cIk:b aut. t6 On 199s-on VZF750SP rno
clicks OUI The IIInIaIII it _

click out. and

1hI1IOtt.-1I1wW1ty-1WO cticl
.........

YZF750SP modeIa - compreulon 17

~~"**"*,,II_

by turTWIg the

adIUSter on the WlOCk absorber

_ o lr 1__ illustration 12.111. Tum Iha adjust. clockwise to Increasa damping and anli-doc:kwlM 10 dec:;ma$e It To IIIIabIIsh the ClJrTWIt M1tIng. tum It-. adjuII.- In jcIockwisa\ ....ttd It IIDP' <;OUn\Jng the mmbar 01 dicks. U>en _

ta

... NCjUir.:I by I.....-.g II CIlJl twenty~. The standard

n..... _

is Ian clicks out. The hardeel ill one click OUI. and the IIOftest II twenty clicks out.

position

YZF1000fl models 19 Sprin9 pre-Iotd adJullmanl is madt a MIfIabII C-sparvw- (or. II prOVIded In 11M looIdt) 10 tun 11M spring - ' on the top of the shock abeortler ,s .. IIIU1trat1onl. There are nina pa.111QOI. Posf\,on , Ie 11>1 eoftesl seilIng. ~tlon • it the standard. poaItiOn 9 U1Ing

Frame, suspension and final drive 6- 23 ~ II. To ..t~ the currin! aeIUng. tum the edj\IIt« In (cIocI<"ooisej \IIIIiI It Slope. 0DtIA1ing the . . . . - CJI dicks. It>tn _ R ..

A!lquired by I........, R out. n-.. ere _Iylour politions . The IlIAdI'd POSItion '- Ion clicks out. The Iwdeet II Ht"O cIicIls out. IIAd the soli_ ito twenty·four dk":b oul

13 SwinsJInn removal aod installatioo 12.20 FIoibound darnping

""-

~

~l Align the ""Itlng ~ with U.. IIId/Ultment Slopper. Tum the IprIng _ t clockwise to IlICresse pre-toad and

II the

Removal Not.: Before r.mcwIng ItMI -.1viSllbIfJ '0 perform ,,,.

I Remove the . . . _

the

1 -. .

It II

,..r suspension

....-l ol ..,y_.

20 R.bo ... nd dlmplng adj ... llment II mad. by Iun'Ion(j the adjIIsl ... on the bottom 01 "" shock I~ 1_ m.... lratlonj. rUIn the 1IdjIaI«.1I d d .iN (as YOO look down all!

13.1 Fr. . the hose from Its lluide

~

checks de&cribfld 1ft C"-P1ftf I to _

8n!ll;1ockwIM 10 <:Iecrease ~.

lrom 11'1. lopj to incr_ dampong IncI cIock_ to decrease It. To ..llbt.-h 11>1 c.......... t "wng, I ...... the Idl..."'" anllcIockWIH .....!II It stops, """"ting 1l1li number of click&, then . - It aa ~ by tumng R 0\11. There . . _ty ~1lons. The .Iandard poelUon II ten cIcI<s 0\11. The Iwdeet II z.a clicIt softest II tw.lty cIcQ 0\11. 21 COmp....lon dlmplnll Idlustmenl is mlde by turnIng the adjuster on the ahock Ibto
s"'l~rm.

. t-

~

ItMI

Chapter 7) IIAd

shock .bsorber 1_ Section 101· On

VZf750R IIAd SP models. hoe the bnoke hoM 'rom the 9\l1de on 11>1 torque ..... 1_

........,

2 l..Irwcrew the bolts MCUring the ~ 10 It>t ~ .-.d ......,..., it. notong how It ' its 1_ mUltretlonsj. R _e lhe IIflIIt pin from "" bolt IIICI.ring lhe brake tOfQ\M""" 10 11M swingarm, then unacrew the nut. wtthdrlow the bolt snd d.tl<;h Ihe a rm along with the tnka caliper tnckal 1_ PhJStratIonj , 3 l.Imcr.w the botUo MCUring the brakII hoM lIuideslcllmps to the 5wlngarm 1_ lIIu l trltlonl j Loop the caliper .,...,. the swr.gam> and position It clear. making ...... 1"IO_.~onlt>tbrthhoM..

I

Bel"", rerTIO¥Ing the swingarm It II

13.21 ChllngUlird bolts lanower;lj· YZF750R Ind SP m<>de>Is

IIIMsabIe to .....::t>eck lor pIey In the t-ings (,.. Ch apt", I). Ivly ","ODI"ml which mly

hive been ove' looked with the olhor luspension cOmPD'*'1I attach..:! 10 the ,..... ... higt1Iigh1ed wtth !him 1ooH. 5 On VZF750R and SP ~, .IAIOYOI the Iron! ~ (1M Secbon 16) ' Unacrew the nlll on I.... and of the SWIfIIIIII1TI pIYot boll and . . . . - t h e _ ( _ ll\lllrltion). Support the~, It>tn . ,thdraw Ih.. pIvoi bOti and remove the Iwtnlllllm , IIonIl with 11>1 <;!rive chaIn on YZF150R aod sp moOe11 II. . lIIul tratlon) . KnOCk Ihe pivot boll Ih'OIIIIh ... lInll a d~ft It required. 1 fIernoYe the ch8in aIIdtr from Ihe Iron! d It>t twhgarm W.-y. notong how ~ ftts 1_ .......-.1. H... t:.Iy worn or .-...geCI. R IIhodd be ~ wittI • .--_.

, Ir...-:t .. c:ornpcrwltIlor _

. . dM<;tIbed In

or damIgoe

SectIon II

13.2b Chalng......-d bOllIll ... o-.l)· VZFlOOOR modell

•

6-24 Frame, suspension and final drive

13.1 ta Locat_ the swlnga"" and InstaU the pivot bolt •.

Insta llation 9 If removed. install the chain slider and tighten Its bolt(s) securely (ne illustration 13.7). 10 11 not alr90dy done. r9tnO\le the cap and washar(s) (where ~tted) from each skIa of the swlngann (Section t 4) and withdrew the collar (see illustrations 14.28 and b). Lubo1cate the bearlngs wtth mo/ybderlum disulphide grease. Also grease the swingarm pivot, the washers and caps. and the ~nkag6 rOO baarIogs in the bottom of the swingarm - remove the collar first and grease that as well. Check the cond~1on of the """I in each cap and replaca ~ with a new one ~ necessary. Ae·install the collars. washers (where fitted) and caps. 11 Olfer up the swin.garm amI have an aMistant hold it in placa. Make ""'" the
13.11b ... making surto the bolt heed"_ locate correctly In the frame sida. Ia<;atlngthe hex head correclly in the frame (see illustrations). Install the nut with its wasItM. and tigtlten the nut to the t<>rqutt setting specified at tha beginning of th .. Chapter (see iltustTatlogarm. ItIen Install the boll and light..., IhII nut to the spacifIed torqUe setting (see illustration I3.2cI. FIt • new spill pin onto the bolt. Loop the caiper over the swingarm. then fit the brake hose guldes/olamps 0<110 the swingarm (see illustration 13.la .... b). On VZF7~ and SP models. III the brake hose Into the tiP-Jide on the torqUe arm lseeillustratlon 13.1). ttle chalnguard (..... 15 Inst.1I illustrations 13.2a .... b) 16 Install the mar wIIII<:II (see Chapter 7).

13.11c Installthewaaher. 17 Check and adjust ttle drive chain slack (see Chapter I). Check the operation 01 the rear suspension before takll'lg the mach"", on the road.

14 SwingarminspectiOn and

bearing reoewa)

Inspection 1 Thorougtlly clean the I wingerm. removing all traces of dirt. corrosion and grease (lee IIluliratlon). 2 Aemove the cap and washer(s) (where fitted) from B&Ch side ollhe swlngarm, then w~hdraw the collar (..... illustrations). Check tile condition of the seW in "",ch cap and replace ~ with a new one H necessary. 3 Inspect aU components closely. looking lor

Frame. suspension and final drive 6-25 Endle. . chain Note : Remov.' requ/ru ~ removal 0111>11 IS dllaj/ed INlow. TIl
A.

W....lng: NEVER In,t.u • drltIa

.....1... /spHtJ

chain ...hlell ule' a ellp-type 1inIr. 5 Remove the • .....-.garm ( _ s.ctIon 13). 1

II RemcMlIIleIrom sprocket (8M Section 18). 7 RImovto ilia chein from ilia bike.

Cleaning otMouI aigoI of wear """'" as ~ 1ICDIng. and crack$ or dlttortion d..... to KcIderlt ~.

ChecIt the DUrings

~

-.

Ior~.

lJeing. drill. to eXtnI(;! the bMMgs. 7 TIll new bearing. 1h0lJ1d be pressed or Or-. Into IIwir bonoI . . - !han Into

_..., oa....s.n.g....-.mg 10 1"*tIon. In ItM _ _ _ 01 •

TooIII.".;I WcWs/Iop np. (Section 5) In tile RtII... eoce sectIOn (1_ mustr.Uonl . Any dlmaged or worn component mutt btl Chec~ tile IwlOQIIrm pivot DOlt for ~by...-.g~on.t'Ia!....-t_"""'"

I

.. I piIaI 01 l*1e gItI.- (I'QI wipe 011 .. old IIfNM and temOYe ..., corrosiorl UIIng nn. _..-y doth). II tile
~

wilt! I

am...

Pf'IS$. •

~

drawboll lIITangerI*1t can be made up . . dncribed In TooIII lind WorlIshop Ti~ (SectIon 5) In the RIt!.......::e MCtIon. Lubrlctltl tile bearings w~h moIybd8flurn dlaulphidl gr-. tr.taIIlhe coa.. IhIn fit till waIheo1al and cap onto NCII side 1_ . .~I • .2b....cl •

15 DrfYI chain -

removal. cleaning

Be.rlng rfJntJwal II A _ a tile CIP and wIsh8f(I) (Whefa fined) I!"om each aide of tile swlngarm. thin w~lIdraw the collar 1_ IllustratIons 14.2a end b). Ae' ... to Tool• .".;I WorlIs/"Iop Ti~ (Section S) In \hi Rel8ffItIO& Mellon lor !T'O:lr1I Inlormation on bNrIng ct..c:b and

--

II Needle boari"9' ctln be dr.wn 0< drilled OIJt 01 IheOr borel. but note that removal will ae.troy them; new bearings should be obtained befor. work commences. PI. . . long drift wiIh • hook«IlItIdlto"ougllone IkIe 01 the Iwlnoarm .nd locale it on IIIe Inner edge 0I1tM ben"Ig on ItM _ aodt. T~ ItM drift IrDUnd the ~'s n- edge to ........... that ~ leaves lIS bore aquareIy. Use the...". method 10 e~t ftlCl the othef bearing. II

.vaillobl•. I slKS.-hammer with kr.Ila-edged r:-Ing ptA.- .... be ...a. _ II bet1. INn

Removal Riveted link Chllin Note: ellalns wlffl • Slaked- type maS11l foinInIiI) W can 0. dsas.-nbloM1 us.I1Q one 01

___

~v.;1abIe

drive <;/laIn

WIltng!'11kiI>g 1001II. Such cn.ifll can be recogrtlMd by the mast... /in~ sJdI pgle', Identl~'1on (anti uwally It3 d j " - t as w6II as by 11>11 "liked end. of the W'a two pins which look as H they"'" I»M a-pIy centl"l-pu1IC"-d. 1n,INd 01 ~ _ .. wfltI .. /he 0lIwr pins. "'" Y2F15CR 8I>d SP models _ lilted with • rltIer..-;lllnlc

""'*"

coIou".

cI¥in .. ,t8tIdwd.

A 1

Warning: Ua . ONLY tha eomet

..,..,I<:a

'h. -"you

,<><>hI to dlsauembla

If-"ltd-Iype of ",..,..- link do not " - K>CeII to auch toc:W or do nol •

ha ... 'he ..IN to

~ta

th .... c""""'/r,

hi... lhe ehaln ....--d by a deal..- HNfcI deparf""",' 0<" bIlIe ,.".". Mop. 1 AlJITIO'o'e the front 'P'OCk
SectIon 16). 2 Locate tI"II joOolIng link In • -.ot.abIe P<*'ion to ""'"' on by rotabng IN bIcIc wheel. 3 $la(;1ten tile d~ chain IS described In

ChIpt.,.

Spi~ tile chain al tile joining link lJeing !tie chain culler. following carefully Ihe menulactur... •• operating Instrucllon. (He Section Sin Tools and ~ 7t:- In 1111 Aef...1lnC1 Sectlon) Remove tile chlin from !tie bike. noting its n>Uting through till

..

-. "*'

C.utlon: Don"

u,e 1I1101lnl (pefrvlJ.

.."...", 0<" Olher dNn4-Ig fluids.

00<1, UN

h/gh·_re .... 1.... Remove lhe eh,,",. w/plJ " off. then bk>w dry " ...hh compre..ed air Immediately. The enllre proc ... • houldn·t Ilk. long" th.n mlnutll _ If h doe • • Ihe O-ring, /n Ihe

'In

r:MIII roIJerI could be ~

Installation Riveted link chain Wlrnlnll: NEVER In.,.11 • drive I chain ... hlch ull• • eljp-type • ..... ,.,.~)HnII.. U_ONLYthe t:
A

and installation

' - .......

a Solk Ihe chain In paraffin (kerosene) lor BpproxirMle/y five or six mIrkltea.

dllplr/menl .... bIlIe ..... shop 10 be ..,... oI~It~ .... ,""'-1 \I SI~ 11M drtva chain through the swlngarm section. and around tile ' ront sproclcet. IN"""" IhI two ends In I t:OIIVIII'Oent poeiIlon 10 W
........ '-«L

C.utlon: U.e only the l"ICommIIndeG

6-26 Frame, suspension and final drive

16.2a Unscrew the bolt !AI and l lida the arm of! the shaft, noting the ellgnment marks (S) Endless ellain

14 Installation is tile reverse 01 removal. On completion adjust and lubricat ~ th~ chain following th e proeedurea described In ChaptEl< 1.

Caution: Use only the

~mmended

Iu~nt.

16 Sprocketscheck and renewal

Check 1 Remove the lower !alring. and

~

reqllired lor

Improved clearance and to prevent Ille possibility 01 damage. remove tile left-hand lairing sIda panel (sell Chapter 8). 2 Unscrew tile gearchange levEl< linkage arm pll"lCh bolt and slid e the arm of! tha shaft, notlng any alignment marks (see illustntion) . !I no mark5 ..... visJ~~. make y<>U" own before removing tile arm so that II can be correctly aligned ....,;th the shaft on installation. Unscrew th" bo~s slICuring Ihe Iront sprockel COv"r and displace Ihe cover (lee illustration) . There Is no need to fully detach the clutch r"lea .... cy1lnder from th" c"""r unless you want to (see Chapt", 2). Nota the po$ition of tile dowels end remove them Wloose. Discard the gask"t "" a new ...... must be kJSed. 3 Check the weer pallem on both sprockets (.... llIustration 1.7 In Chapter 1). Whenever tile sprockets lI(e Inspected the drive chain should also be Inspected. " the spro<:keltaeth ar" wom excessi'o'eIy, or you are fJlting a new chain. renew tile chain and sprockets as a set. 4 Adjust and lubricate lhe chain loIlowing the procedures described in Chapter 1. Caution: Use only Ihe recommended lubricant

Renewal Front sprocket 16.7a Bend back the Iockwashertab(s).

t15.7b ••• then unscrew the nut (arrowed)

5 R8ITIO\'e tile lower fairing, and" requil'9d!or Improved cl&aranc" and to prevent the

19.6 Slide the sprocket off the shaft and

~-"

possibil ity 01 damage. remove Ihe left-hand fairing sIda panel (see Chaplet 9J. 6 Unscrew the gearchange lever linkage arm pinch bolt and slide the arm ott the Ihaft. any alignment marks (lee noting illustration 16.2a). If no marks are viSible. make your own before removing Ille arm so lhat ~ can be COfl"ecIly aI;gned with ~he shaft on installation. Unscrew the bolts securing tile fronl $prOCk"t cover and dlsplaoe the cover !see Illustration 16.2b). There it! no need to detach the ciutch release cy1inder Irom Ihe cover unl"ss you want to (...... Chapter 2). Note Ihe pos~lon 01 the dowels and rerno~ them il loose. Discard the gnkets 85 new ones must be used. 7 Bend down the tab(l) on tile $prOCket nut Iockwasher (see IIlustrptlon)_ Have an asslslant apply the rear bral<e hard , then unscrew tile nut and r"""",e the washer ( _ Illustration). Discard the washer as a new one should be used . Reietto Chaplet 1 Md adjust the chain so that k .. tully slack. 8 SHde the sprockal and chain ott the shah and slip tha sprocket out 01 the chain (see illustration). If there Is not enough slaCk on the chain 10 re<TIO\'e!he sprocket. disengage the chain !n)m the rear wh~ 8 Engage the new sprocket with the chaTn and slide rt on the shaft (see illustration) . Take up the :;Jack In the chain (sea Chapter I ).

16.11 FTt the sprocket into the chain and slide it onto the shaft

Frame, suspension and final drive 6-27

A IS.IOb ... andthenul.

16.11a Fit !he main gasket, locating it onto the dowels (amowed) . 10 Sfid~ on the

""w Iockwasher, then m the

nul and light"" II 10 the lorque setl ing spe<;llle(! al lhe beginning of lhe Chapler, applying Ihe rear brake 10 prev&f11 Ihe sprockel from turning (see iI1u ~ lr a tlon .). Bend up lhe labs of II>!! Iockwash... against the nut (see Illustration) . 11 H removed. fit the sprockel cover r:Iowels IntOlhe crankcase. i!\Stall the cov. using new gaskals and tighl&f1 its bolts 10 the specnied t<>!! shaft.

alioning the mar1<s. and tighl"" lhe pinch bolt (s... Illustrallon 16.la).

Flear sprocket 12 Removelhe_~(_Chapl .... 7). 13 Unscrew Ihe nuls secufing tl>!! sprocket 10 the hub assembty (see mu.l.allon). Remove tha sprockel. nolong which way round It lits. 14 InslaR the sprocket 0010 the hull

w~h the stamped mark lacing OUI. nghl"" Ihe nuis evenry and in a c,;,,~-cross seqU&f1ce 10 II>!! torQue s"tt ing specified al Ihe beginning 0 1 the Chapl ..... IS Install the rear wllM (see Chapt ...

n.

~

17 Rear sprocket coupling/rubber dampen; -

~ ~

check and renewal

n.

1 Remove the """ wheel (see Chapter Caullon: Do nol lay Ihe wh-' down on Ihe disc as II could bllN:om e warped. Lay fh. w".,.,1 on wood&n bloch so fhallhe diac Ie 0" th. ground. 2 LIlI the sprockel coupling away trom Ihe ~ leaving the rubber dampers in posillon in Ihe wll" (Iae IlIu" ..llon) . Not" Ihe spacer inside Ihe coupling - it shou ld be •

8

16.11b . .. &f1d _ small gasket, using a dab of grease to hold It •

6- 28 Frame, suspension and final drive tight fit but _ II II It '- INIy 10 <*'09 out. Check 1tl& COUJliIng lor cncks or any oIMouI tlgns 01 damfoQe. AI.a check the sprocket ,Iuds for we. or~. 3 un the rub~ damper Hgments from the

-

wheel and check them 101' cracks. hardening and gener.1 deterioration 1_ Iliulultlon) . R_w the
. lind • ChecImg

~ ~

lor

!he aproo;I<et coupIng bNring WI dacrIbed

In Chapter 7.

.......

17.2 uti the sprocket coupling out 01 the

5 InstaIatlon '- the ___

17.3 •••• nd r . - the rubber damlM'W

....... the spaoer '-

0I~.

Make

_tw QOfT.ctIy WIstaDed In the

coupling. or . .181111 W~ wlUl _ l i d . II Install the .ear wheel ( _ Chapter 7).

7"

Chapter 7 Brakes, wheels and tyres Contents Bfab IIuid w.eI chick ._ o.uy~~ BraI<e ' - . ~ .00 ........... -1repectJon ..0 . . . - 10

~

Bl'8ke1lghl~-_ItId__

RMr bake ",.... qtIndet - ...-.-.I, o-erhIIuI 8IId ....taIIatlon

BtakepIICI _ _ '.

.-Chapt.,

_~9

Brakoo fYSt.... bIe«IIng 11 I)'Stem chick , . _ ChtIpW 1 FronI tnke ~ -.-.-.I. owrI'IIU ItId NtaIIIoI:oon 3 Front tnQ
ar-.

Front tnke!*ls - _ _

""""'-

brMIo ea»p.r - ....--I. _ 0YeITIU NtaIIatIon _ _ Ind _ .........,.,

-.--aI .

~bra k. pads RMrwhelll _ _ _ _ lnstlllallon.

,. 1

fj

6 . .... 15

• • ..•• 11 T.,.... _ Womwtio _ ...nd.-.d condition . _ o.ily p.-ndI) CMcIIS Wheel '-Ings _ _ . . ...... _ Chapttr 1 ~-1IIf*III

~

Wheel

~

-

doIIpIh

~

.....,....Inspectlon and InIItallalioo

....,.....-~_

FronI ...... - _ _ _ wad inIt8IIIobOn

1I

RMrbrelo:edllc-~

WheeIt- gener8I check .. ....,.....-~_repair.

••• 16 ..... 13 . _ ChItpI4o" 1 , 12

Degrees of difficulty

_-

Specifications

....... .... Brakes

_ .... -_ ----

OOH

Front cabper bore 10

VZF750R .00___ SP rnocIIItI Upper a'Id !:lor-.

27.00 INn 25 .• 8mm

VZF1000Am<>
3O.2Omm 27.00rnm

Front dIIc: tho::I<..u

S'""""

Servic» Iorrit

Front dIIC mumum IIMICUI FronI . . . . . ~ bore 10

YZF750R IIld SP modo!Is . vzrl000R~

~ctlliperborelD

....

S"""" .

5.0mm •. 5mm O>~

15.875 mm 1•. 00 rrvn Q.80rrvn

8.0mm

5.5 nvn

RMr dille maUnum tmout

0.15",,"

ReI< n'I8S\er C)'Iinder bore 10

1•. 00mm

Wheels

"""',,

....

n. MT3.SO 17. MrS.5O

AmI~~)

O.Srrm

RdII \OuI-oI-round) •

'.Omm

,~

Wheel runoul (max)

Tyres T)'I'e

~

_

Deily II:W-rideJ ch«:kJ

T.,... .....• FronI

12Q{7o-ZRI7

Rear 'Refer 10 It.

1801S5-ZRl1

_1IandbooII, the

ry.. ...1'otmUon IM»I on the swlIIQIWm. OF your dMItIF II::w ~ lyre IntIds.

7

7-2 Brakes, wheels and tyres Torque wre nch settings Front brake caliper ITlOIJnting boks VZF750R and SP models .. VZFl000R models ... . .. • . . ......... • . Brnk" I>osII banjo bolls YZF750R and SP models . YZF1000R models • •. Front brake disc bolts Front brake master cylinder c lamp bolts YZF750R and SP models YZFHlOOR models Rear brake cellper mounting bolls YZF750R aod SP rnodeIs YZF1000A models Rear brakll disc bolls . Rear brake mastercylK"ldl!r ITlOIJntJng bolts . Bleed valve • . ...... • ...... • . . . .. . • .. • . • .. • . Frontwhlllll ""III VZF750A and SP models .

YlJ' t OOOR models Fronl axlll damp boll Rear ""III nut 1993 and 1994 VZF750R and SP models 1995-on YZF750R and SP models . .. . . . .. . . ... .. . . . YZF 1000R models

1 General information

All models are fitted with ClI!It alloy wt>e<>s delligned for tubelllss tyr"" only. Both front and rear brakes are hydrau lically operated disc brakes The front !>rak"" arll tripllt opposed-piston calIpers on YZF750R and SP models. and twin opposed -piston calipers on YZF 1000R

35 Nm

"' Nm "' Nm "' Nm 23 Nm 10 Nm 13 Nm

"Nm 40Nm

"Nm "Nm 'Nm 12Nm 70Nm

"Nm " " Nm 150 Nm 150 Nm

model!l. The rear bo"ake Is a singlll opposedplslon caliper on 811 rnod8Is Cllution: Disc brilke comporlerlts rllrely require dislls s.mbly. Do riot dlsllssemble components IIn"~s IIMo11lt1l1y nllCIlSSIIry. If II hydraulic brakll Ilnll Is looslIned, th ll IInl;", sys lllm muSI be disllllllmb/ed, drllined, cl. .rled .nd Ihen property filled a nd b/tJd upon re/tsse mbly. Do not u s e s olv_nts on Inlllmill brakll components. SoIvllnIS ",III ca,," Ifill seal5 10 sWII11 and dis tort. Use Orlly cl"an bnoke fl,,1d or

d"nalured alcohol for clean/rig. Use care ",hlln working ",ilh bra ke flu id as II can wi" damllfJfl painttJd wrtaces and plastic parts. irljlN"fl your ayes lind It

2 Front brake pads -

"",ow.

~

ill -

Warning: The dust c....ttJd by tIIlI brak" system may conlllin

a sbes tos, which Is hamtf,,1 to your

hllillth. Ne"", bIo", It out "'Ith compressed air and don't /nh.1II arly of It. An approved fmltring mask s hould be wom wherl worlcing on I!>II brak.... 1 On YZF750A and SP mod~ s, remove the r"'s inin g clip from eech pad retaining pin. then wlth<:lraw the pad pins. noting how they locate through the pad spnng (SII_ IiIustratlons). ~ the pad spOng. noting which way round il filS (' 4111 IIII1.tratlon). W~hdra w thII pads from the top of the caliper, noting how they f~ ISH illlIStJatlon) . Remove the shim from the back of each pad. noting how it filll 1_ Inustnotionj.

2.1 c ••• and rflmove the pad spring

2.1d LIft the pads out 01 thI! caliper • . •

2.1 •• . • and rfln>OV" the shim, whIIfe fitted

Brakes, wheels and tyres 7-3

2..2a R .... o .... the retaining elll" '

2 On YZF1000R models, remove the relainlng clip from .... eh &nd 01 the pad r"'!lining pin, thom withdraw the pad ~n, nollng how It

locates through the pad spring, and rernO .... the pad spring, ""ting which way round it fits !s_ 1IIustretlonsl_ Wlth<:!raw the pads from the top 01 the caliper, noting how they fit!see iIIustrationl. Remove the shim from the back 01 each pad, noting how it Iits (SH illustrallon). 3 Inspect the su rface of each pad lor contamination and chftCk that the Ir!cllon mat<W1a1 has not worn beyond ~S ~ lim~ (see Chapter I, SftCtion 8). 1/ e~her pad I, wom down to ... beyond the ,......,;ce ~mi1 w8llr indicator, Is louled with 011 or grease, or Is hea"'ly scored or damaged by dirt and debris, both pad!J In &e<;h cal;pw musl be r&rIeWed. Note th~t it is not possible to degrease the IrIction material; II the pads ..... contaminated In any way new 0r\9S must be fitted. .. If the pads .... in good condition cII!an them carefully, using a I I.... wire brush which is completely fnw 01 oil and II""""" tc remove .. trace. 01 road dirt and corrosion. Using • pointed Instrument, cjean out the grooves In the friction material and dig out any embedded particles oIltnign matt ... My ...... 01 glazing may be removed using emery cloth. Spray With a dedicated brske cIeano!io" to remove art)' dust. 5 Check the condrt"", 01 the brake di$c ( _ $ftCtion 4). 6 Remova all traces of corroo.ion from the pad p;n. Check ~ I... signs 01 damllQl! and renew ~ ij~.

7 Push the pistoos as lat back Into the caliper as possible using hand pressurfI or , pjeoe 01

2,2b .,' th ... withdraw the pad pin and remo .... !he pad spring wood ,,"leverage. Due to the Incnoased friction mater\lll thlckr>ftss 01 new pads, rt may be oecessaoy to remove the fluid ~f cap, ~ate and diaphragm and siphon out some ~uld. II access to the piston heads Is too restricted ""'" the caWpen in ptace, l6'IboIt the caliper Ifom the lorb (..... Section 3). tI the pistON! are difficult to PO"" back, attaoh e length 01 clear hose to the bleed valve and ptace the open end In • suitable contme.-, then open the valve and try again. Take gr6at can!I 001 tc draw any Into the system. 1/ in doo.t>I, bleed the bmkes att_1Ids (see Sect"", II). 8 Sm80r the bacb 01 the pads and the !!hank 01 the pad pln(sl with copper·based grea" , making SUre that none gets on the front Or sides 01the pads. /I On YZF750R and SP models, lit the shim (where tined) onto the baCk 01 each pad, ma~ing sure the arrow, _ e ~t, points In the direction 01 normal di"" rotation !see lIIuatrallon 2.1el. Insert the pads into the caliper so that the Iriction material of each pad lac... the di$c ( _ illustration 2.1<1). FIt the pad spring O<1to the pads, maletpad ! SH illustration). Install the retaining clips, using new on,," If nece5sary !aee lIIustrattonl 10 On VZF1000R models, fit the shim (where fitted) onto the back 01 each pad, makirlg sure th" arrow, where present, points In the

2.2c un the pads out oIlhe caliper ,

'*

2.2<1 '" and ramo .... the shim, where fmed direction 01 no.mal diae rotation !...e lIIuatratlon 2.2<1). Insarl the pads Into the caliper so Ihat the IricHon mat ..rlal of each pad laces the disc!see lu...traUon 2.2cl. F~ the pad spring 0<1\0 the pads, making sure the arrow (wh ...... marked) points lorward, in the direction 01 normal dlae rotation !SH Illustration 2.2bJ. Insert the pad retaining pin through the hole in the outer pad, then P'"""" down on the pad spring and posh the pin through the spring and the hoi.. In the In~ pad (... Illustrallon 2.2b). Install the fetaintng elil", ...ing new ones If necessary (see illustnotlonl . 11 Top up the master cylinder re"rvorakn Ie....... " " " ,aj times to Mng the pads Into contact with the disc. Check the ~ion 01 the brake before riding the motorcy<::le.

.--.....----,

7

7e4 Brakes, wheels and lyres the brske hose to the mudiluard (sa. liI.ntnotlonsj. 2 ~ the caliper.! are JUSI belrog dis.placed and root COI'I'lpletely removed Of overhauled. do not disconnect the t::.-ak~ hose. ff !he caUpers are being comp letely removed or overhauled. remove !he brake hose banjo bo~ and detach !he hose. noting ~s BligrvTlllnl with !he celipef Isee illustrations). Plug !he end Of wrap a plaslic bag tightly around to minimise ftuld loss and prevent dirt enlerlng the ~ystem. Discard !he sealirog washers as roew ones must be used on installation. Note: If you .,. planning to overh8ul the CBIipty fIf>d don" hBve a source of compressed sir 10 blowout lhe pistons. just loosen the bI/niD bolt al thi5 slage and /"tHigh/en II IIglltly. The blke·s hydraulic systam can then be used to Ion;a !he pistons OUI of the body O""e the pads have been removed. Disconnect the hose once lhe pistons 116"8 l>e8>l sulf"lCIent/y dIspIaoed. 3 Unscrew Ihe caliper mOUllting bolts and slide the car.per off the disc; on YZF75QR and SP models note the ~ .... cable guide secured by the lower bolt on the left·hand caliper (He IIlustraiIOlls).

nc-

models. ullscnw the IlUt and withdraw the bolt securlrog the brake ho... clamp to the mudguard

3 Front brake caUpers removal. ovemaul and

Installation

~

$

~

don'f Inhale any of It An IIfJPI'Oved filtering mask should be worn will'" worlclng on tha bl"altes. Do not, ulldsr any clrcumstancas, use pelroleum-based solvents to claan brake pam. Use the lJPfICirlSd clean bntke fluid, ~tfld bnlka cleaner or demlfurec/ alcohol only, as describ«1.

Warning: If a caliper Indfcstes the , nfHKIlcr In overl!luI (.nullity due • 10 lealtlng fluid d. "iCky oparslionJ, all old brs'" fluid should be

A

Re m oval

flushed from tha systam. Also, Iha dust crestad by tM bra,.. systam may contain Isbeslos, which Is ha""ful to yoor hNlth. He.... blow It out with compreS$Sd el. end

1 If !he caliper.! are being ovamaulod, "'"""'" the braka pads [see Seclion 2). If the calipon are jusl belrog displa.ced Of removed. the pads can be lett in plac
3.28 Braka ho ..... banjo bolt (arrowed) VZF750R and SP model.

3.2b Brake hoM balljo bolt (arrowed)YZF1000R models

3.3a caliper mounllO{j bolta IAI- VZF750R alld SP models. Nota the cabl. guide {Bj

Overhaul 4 Clean Ihe e~te,ior of Ihe caliper with danatufed alcohol or brake system cleaner (He Hluslnltions). 5 Using a nat piece of wood. block !tie pistons on anti side of the caliper III their bores end displace the opposite pistons either by pumping them out by operating the Iron! brake I ~ver, or by forcing Ihem 01.11 USing compressed afro Remove the seals (see below) from the bore of lhe displaced pist"""" then remstall the pistons and block them using the wood. Now displace the pi!:;lons from the other slde u8irog the same mel hod. Remove the wood and all Ihe pistons. Marl< eaCh piston head and caliper body with a felt marl< .... 10 enSUf1I that the pistons can be malched 10 their original bofes on reassembly. If the compressed air n"llllhod is used, cf.-..ct the air

Brakes, wheels and tyres 7- 5

3Aa Front brake caI/pM' ............... _ 'YZF15OR _ SP rnodtIlI I twl'"

A 1

In front of tlla pl.,on. In a n

•

attempl 10 calch or pnllact tttam COtnprMMd air. . . .".,...

""*' appIyfng

cwtiM: 00 no! fly 10 _ IfIe piJfons til' --~ """"*' " INn! out. or by '*"'" p/ieII or any 0'''''' grlpa. On 'rZFlotXIR modah, do nol al1wnpllo _

Ina.,..,. __ a,.... CAlIPer.

pIufp .....

0I1ha or _ _ aIdft 01 II Using a wooden or plastic tool. _ thoo dust H.la Irom the callp&f bores I' " IfIe

~

ihI<.!nsI fIN _

fIN~.

_..-

~­

PlJron

2 AsfOtI...

inCo the fluid ioIeIto force the pisloos out 01 1M body. lIM only low preAUnt 10 _ the pisIon. outlfld make ...... both pisloos on the • kn concerned .... displaced al Ih. sarne lime. II the air pr ........ I. too hil;h aoo the pi.tons ara forced out. lhe caliper and/or ~ mty . . CIa'naQIId. w..,rn"g: _~"J'O'N1IngMs

3.4b Front bnoke c.I __ VZFlOOOA rnoo:IoN 2 AsfOtI...

I l:lJsI __

"""trillion). 0iIcard ~ as ' - Cf"oIII ......... De UHd on lnItallatlon. If • metal tool II ~ ..lid. lak, "".t ca ... not to dama,,1 the callptr bora. . 7 Ft_e l1l(I discM
_way. II ClMn 1M pillona aOO bores with elMn braka "uld 01 tha ""eeillad type. II comprWMd . . II .... ~ .... ~ to dry the pemc IhorOUQhIy lmake ..... 11". liI1erad and

.......,...

-

c.uIfOI"I: Do not, ..,... any

~

u.. a patroMum.ba_.-, 10 _

.....

f Inapacl the caliper bores and plllona 10< noc:kslfld buTs _ lou 01 plating. It ....11_ ""'acts .... pruant. lhe callplf ....... bly mull De ren_ed. II the .-ury meat.urInII eQUIpment Is '''aOla~. compare the dlmenslons of the callper bora.

.q.

af~.

3.11 UH. pIaetic or wooden 1000IaudI • • pencil) 10

:1 AsfOtI

to lhoM spaclflad .t the beginning 01 the Ch.pt.... and Install I naw caliplf ~ nee.....,.. lithe caliper Is In b..:I shape the malt. cylloo. ehouId also De ehacked. to Lullorbt. the ' - piston Hals wt1h cIMn btaka ftuk:I and InItaIIIt>em In their ~ In 1M c.sper borw. Nota thai two m. 01 bOre ItId piston .... used ( _ SpactI\caIJ
.au _ ..

"'--

_ftuld_lnataIItnemlnthair~1n

12 lubricate the pistons with cINn br.ke fluid _ InatallIhern cIoeed-and1Ql Into the callplf borN. Ualng your thu-mbs. puIh the pistons" tha wav In. making ...... thofy ..., • the bora squarely.

7

7- 6 Brakes, wheels and tyres Remov,,1 •

~

the wheel (see Section 14).

C.,,'/on: 00 not,.,. lhe wheel _ n Ind _ I f 1 0 _ ..... the dOsc_ the dlllCcouId ~ w.rpMJ. S.I lhe wlleel on wood bloch .0 di.c dosan 'l support III.

'h.

~Iotlhe"""'"

,-

3 .14/) •• • ndtlg~themtothe~ II the

Inst"lI" rIon 13 H- V . puIh the

pI$!(Q

IH!lew..,

t.:k InIo the eaIiJ* I.eing ha1d presao.n Ot I pIKe of wood . . ~. SlIde the caliper onto the tnI
, .. '~'" the c;ah~ mounting bolts. on YZF75QA Ind SP modeIa. not lorgettlng 10 II8CIft the apMdomeI. cable gvIde """" ltoe low... boll on I". ~ ft -""nd caliper la. . 11I"l t'ltlon 3.31). Ind tighten them 10 Ihl lorQul setting lpecilled 'Ilhe beginning 01 the Cilapl. 1_ IM",tretIOttI). 15

~innlng of the Chapl •. Top up the cyI~ .-voir with DOT .. brakl

.....t.

fluid 1_ o.IIy tt--ffde} checks) and bINd the t.ydrlullc .)'It.... as doMcribed 11'1 $oocbOn II. Ie II ~. Inslill the brIkI padl 1_ s.ctIon 21. SeoutIthe brake ~ 11'1111 ~ 1_-.-.atIon 3.1. orb). 17 CI>KII lOt I"..,.. _ ItIorouoghly '''' ltoe opetllioo 01 the braJ<e belo<e ri(ling the

-,""",.

1f ~.C
CllIPI"'. ualog roew _' ~ was/le<s on QoC/1 IIde 01 the Iitto:'og. AIIgrIthe ~ as II01ed on

............ iSH

,.....tnt\on 3.2l1 or b). TIght...

the bw$I bolt to the tOfQlJll eet1ing specified

Inspection I ViIuaIIy Inspect the .....-r- of the disc lOt marI
-.;rlla-- arl

.-m'"

'ag.

.. .2 Set up • dial IndIc:ItOt with the probe eom.ctlng the linin
~ ..-lie. oomprwIng trw .-ling with trw limit listed In 11>1 $pecIficalio/w II 11>1 tIeogInning 01 the Chapter. II the nII'IOUl ill grMI. IIwIIhI ..w:.1irm. ct.c:II the whM bNrings 10< play 1_ Chapt. 1). II tn. belrIngII .,. worn. ....,IlII new ones Section 16) and repeet this check. lithe dItc runouI iIIltill~. I roew _ .... MvelO tie IIIled. "'though machining by an ~ may tie pot.. . . . 3 The disc must nol tie machined 0< IlIkw/ed 10 we .. down to • Ihlcknl!!ltl Ins thin the ...... k:e limit as listed In thl. Ch.pt..•• SpecIIIcatIonl. The thIckoess 01 the disc can tie cI>KklCl whh I micrometer Of any OlrmMsurlng 1001 I'" Ulu.trltlonj . II the ~ 01 the dec ill .... th8n the..wee ih"OI •• '-_....,tlefittlCl.

r-

II Mark the reIIllooship of '1M disc to tn. wheel. to ~ can tie InSlal ted In 1"- ..,.,. position. Unscrew lhe dlac .. lalnln.g boIlI. II>oIInIng lhem """"'Y and • liltle . , • IIrnI!III'I • cfill-cron pattern to avo~ dhllorting 11M disc. IMn remOVI the dlac Irom Ihe wheel 1_ Inustrlltlonl

Ins tlll/Il tlon , Mount the dISC on tIM w'-I with ~ • m''''ed MIl l.clng out. aloj»nong t.... ptIYIouIIy toppled match ......... (11 )'011'" -..ng !hi 0I%JrlIII diIc). 7 Clean the thrNda 01 !he disc mounting boIIl. lhen

~

I ",n.bIe noo-pwmanent

IhrMd Iockillg compound. lnatell ,he bon. and t.ghtln tha"n -.tv.-.l.1IttIe II I \me in I cr1..-crolll pan ..... 10 lhe lorque "1I1ng ,peellild It lhe beginnIng 01 'h. Chepler Clean off "" grMM ifom !hi brak, dIIC I.IIIng Icetonl or brlk. s~sl9m eIMn .... II • nlW brake disc has I>Hn InSlatled. remove any protective co.t"", from ill working lIUrIecII. Ii IMtail the front _ 1_ Saction 14). Il Operele the brake lever _ & I tl/TIM to bring the pad, InlO contact with the disc . Chlcll 1111 operalion 01 the brakI$ earefuIf\I before IIdWlg the bikI.

5 Fronl brake mastef cylinder - removal, overhaul and installattoo

~ ~

~

1 It the masl. cylinder II. ~ fluid. '" ~ the lev.- does nol produce • ~rm IIIfII wilen the bra'" ill applied. and bIMd~ the bnlkII d".. nOl help (see Seclion II). Ind 1"hydrlOlJllc hoMe ... all WI good condition. IhwI mulereyilnder overhaul Is ~ 2 BeI"'1 dluuembliIlg!hl IT\IIII. cylinder. ...., ItIrough the . .lire procedure and make ..... IIMII )'011 hive the C(Ir. ecI rebuild lut Also. )'011 wll ..-I ......... new DOT 4 Drak. fluid. some clean r.gl and Inl""" circIIp

Brakes, wheels and tyres 7- 7

pIrL Now. To ~.,.". /0 ~ pUrt Imm ~ tIt* /t.JkI. IIwttys c:o..... ~ fueJ I&'I/r.,."." worfQoIg on ~".uw C)4I'Idw. OiU'Hmbly. ..........bIy of m.Il., cyli"der m..11 be do". ,,, • cl<"", ...ork I .... to 1 !fOId conl.mln.llon end pouJbIe

C.,IIIO,.,

f,JI.. ,. of

-"

,h. ",..spot""" ... 0...,.,....'

,h_

br.~_

"yd,...,1<:

."d

~y~ l .m

Removal 3 ~.... 1"- ........,.. cap clamp ....:I ~...-.c:r.w the c.p ( _ ..... lnItionj . 4 Disceonn.ct t"- brakl light ..... llch .... irIng COr"OlICtOtS 1_ MIu~ . 5 II It... mut... cyilnOer. bIoing overhauled. ......aYe ttw /font ",.... ,...,... 1_ Chllpt ... 6). If ~ IIIV11 being d~ed ~ CIlIlI"llfl"llin In ~IU. , II tile mister cyiloOlt Is being comp"'tely

removed 01' cwlrh ... IId. unSCrew the brlk. hOM DIInjo boll WId ' - ' " \tie r.o... from tIII...sl.~.noIirIg\tle~ (_

HIu,tlltlonj. D1Kord 1hI MaIiog wuhIra .. they ITUII be . . - with rww~. Wrep IhII .".;1(.) 01 the '-"I') ", a ~ rag .nd -..pend !him In . . upIght IX*tion 01 \him down Cll"lfully wid pilei IhII open "'(1) In I dMn ccntMwr. The oo;.::tMo II to pI"I'O'erIt .x~ Iou 01 br.k_ fluid. I\uId IPiIII n ~"" contamination. If till mast. cylinder I, Il.IIt being dlsptaced and not comptetely rem
..

~

IhI brIka r.o....

'*'"

7 ~ IhI boIt..,..;"g 1"- ......... 10 Its braCket. thin rIrI"IOYe the -"'* cap n lift off lhe dlaptvagm plale and !hi rubber diaphragm 1_ Illustration 5.3). Drain the brakl fluid from IhII reservoir into. tuilabil contsl_. Rele... the clamp securing the ' • ...".olr hOM to the union 0fI the mISter cyllnd.... th.., detach the hoM 'HI lII",traOon). Wipe any remaining /\uK] out ot the ......... willi • cleen rag. a I./nscfIW the mast... cyfonder clamp Il"wI lift the master cylinder away from the r.dItIIr !HI ilu5u.t1onJ. II If~ • ......,.... the ocrew....:umg the

-

bOlt,.

....

tdkIl9hllWitd"IWldrlrl"lOYelhlswitd"l ~

C.IlIIor>, 00 ....1 'Jp ",. mas'... cyIJmI....,.e/dI down or bra*1 fluid ........ out.

Overhaul 10 Ca..llully ...--. the dual bool ' rom 1"-

mast. cylinder 1_ MI...tretion-i. 1t

lJIInQ dn:11p pliers, ramove the eirclip .-.d

7

7- 8 Brakes, wheels and tyres

5.1Oa Fronl

rna.,.,. cylindar components -

15.1Ob Fronl m. .ter cyllodef COITIpo.....,18 -

VZF750R and SP models

.-

2 0n::IIP

5 C»cfp

3 PIston ~end

6

~""1A'1Ion

7 O-mg

IfPri'lg

-'Ida out the pisloo auembIy end the spring. noting how lhey I'll ( _ II\>SIrIItlon) . t..y the

part. OUI In IhI! proper Ofdar 10 Playeol confuaion durIog reassembly.

no..

12 Ramova lhe fluid rtlServoir union ru~ tap, IIIen r.roo... Iha clrcllp and dataeh lhe union from 11110 mull" cylinder. Dilcard 11110 O-ring lIS I new one mual be ~. InIpKt the ,...,a. '-lor cnc:b or 1pIiU.nd _if~. 13 ClMn III parts with clean brakl ftu.Id. It ~ air Is availallla. use it 10 dry the pat1t thoroughly (make lura II', lillered .net unlubricet.cl). Clullon: Do nol, under any clf'eum.lances,

.....

-

YV'1000R models

~ cap

1 RI.otIber boot

u.a a petroleum-besed aolvant 10 r::lean 14 Check lhe masler cylinder bofa 101'

oorroeIon, ~ rIic:b er1d IKlOnI marI<e. It the .-sary ........ t1ng equlpmenl Is 8Y8iIabIe. 000'4)8I'e the dier!>eler 01 the bono 10 Ihet ~ In the SpecifIca~ SeetIon oItm Cl\llpt .... II damage 01' weer Is evId .... l. Iha me,ler cytinder must be replaced ~th I ~ one. It Iha mISter cytlnder Is In pool' condil"", then the caliper.! shovid be en.clted es WIll.

Check tl\ll, the fluid INeI end outlet port. In the mu'ercyilnder ... dear. 15 Tha dUll boot. clrcllp. piston assambly and $pring ..alnc;luded in the rebuild klt. LIM all of the new parts. regardl... 01 the apparent 01 the old ones. Fit In.n according 10 !he '-yout of the old piston

-.

condit""

lIS F'~ the tpring kilo the ~ eyIinder. On VZFl000R rnodtIt lit; narrow and IIhouId ' ~

17 LubrIcIIta the piston assembly with cIaen brlk. ftuid. FII the nsembly inlO the ...... t.. cyllnd .... making 'ura II I. Iha correct way round. Make IIIrtI the ~ps on the cup do not IJ,.m ~ out whan !hay ... sliPJ*llniO the bono. 08prtIu the piston and inaI.. the . clrcllp. maklng turtl thai it IocIIt.. In lhe groove 1_1IuoItrrion 5.11). 18 InttIIII the lUbber dI.et boot. making ...... the lip "'.-lad ~ In the ~ 1_ muslnlilon 5.1Oc). 19 Fit I new O'rlng onlO the ~r hose unkln. lhen prell tha unkln InlO the .... s t... cytinder ertd Me..... it with thll clrcHp. Fit the rubber cap over the clrdp.

20 Inspact lhe reaarvolr cap rubb8!' diaphragm .nd reoaw II If II Is damaged Of o.terlorated.

IndBllation 21 If 1'l!IO'\"KIWod. instill the brw liglhl swildt t_lIIustnoilon 4AI 22 Attach the mast.. cytinder to lhe handIaber and f!I the clamp with Its 'UP' mn facing UP. aligning the lop meting IUffaI:es ~ Iha clamp wllh Ihl punchmarl< on lhe I\IIndlebaf (He Iliullrllion 15.8). TIghten the upper Dolt firal. then 11\11 low ... Dolt 10 the 1O
24 If removed. Inllill Iha brakl laver t_ Chapter6). 25 Mount the rMMYOlr Ind Ilghlen the bolt securely (... lliullratlon 5.3). Conrtld the .....,. hose 10 !hi union and I8CUnI it with the damp t_lIMtrMion 5.7). ze Connecl the brlka IIgItI Iwltch wiring connectors ( _ lIullnlllon 5.41. 27 Fill the ftuid r.-.rvoIr w,lh new DOT 4 braka fluid 85 dHCribad In ()ajly (pr&-rlda) Cflecb. Ref.r 10 Section 11 01 this Ch.pl ... and DIeed the IIr from the IyIItem. 28 F'~ the lUbber diaphragm, making ....... h .. c:omK:Itf seated. !hi cIIapIngm plate ancf the cap onto the master cyIndar .....,.. Ihert ft1 !Ita cap damp 1_1IuetrItIon 5.3). 2!1 Check the O!*'ailon 01 the fronl btIoka

baIOIlI riding the~.

Brakes, wheels and tyres 7- 9

6 .1. Remo ... the cellpel' CO\IIlII".

8.1b ••• then remO... the retaining cll~ tAl. wlthdrawthe pad pins (B) and remove the -">II (C), noting how It fits

neaviIy !lCored or damaged by dirt and debris. both pads mus l lMt reMwed as a ...1. Note it is not possible 10 degrease the trk;Iion matlllial: H the pads are contaminated if1 any w~ new ones must be fitted. 3 n the peds ..... if1 good condition cIear1 them

t~

h..

Lll.

WamlnSr." 711 .. dust ."...,.Iftd by the

bra ke

s ys lem

may

conlaln

"basI.... which Is hamtlul to fOIH he8IIh. N_ blow /I out whh compteS.SOId air _

don't Inhllla any of It An approvaod

fiN_ring mu ll sllould be wom w""" wot1
bladed !Crewd"",,,r il necessary II-H iIIus traUon) . Remove the pad pin retaining clips. th .. n witMraw the pad pin. from the caliper using a !IIlila ble pair of pli",s and remove the pad .spring, notng how ~ filS 1_ lIIu. tl-allon) . WitM,aw the padS f,om th, ctllpe( body (. ... IIlus t .. Uon) . If required. ,emove !he arrtl-chatt .... shOT! from the back 01 .... ch pad, noting how It fits (see Illustration 6.7)

2 Inspect th .. surface 01 each pad 10' contamlnatiofl and check that Ih .. friction malarilli has not worn beyond its service limit (s"" Cha pter 1. Section B). II .. ither pad I. worn down to or beyond the service l i m~ _ Indicator. Is fouled wllh ,"I Of" grease, or Is

carefully. using a fine wire brus h which Is completely IreIII of oil and grease to remove all trace s 0 1 road dirt ann. Using a pointed Instrument. Clean out tha groo_ in Ih' Irlctlon mal"";a) and dill out any embedded particles of lonogn matter. Any areas of glB2ing may bG 19I11OY8d usjog aToII!Y

-.

cloth. Spray witt! a dedic8ted brake clelw"ler 10 remov8MY"'-"'t • Ct>ecI< the condition 01 the brak, disc (we

5 Ramon al traces or cOfTOSior1 from lhe pad pins. Check them for silln. of dam ag.. and •eoew them wnecessary. e Push the pislons as far bacl< into !he caliper as pos$bIe using hand pt'8S8UI'(t or a piece of wood as ""'"""II". Due to the increased friction matarial thickness 01 new pads. it may be n8CfttI""'Y 10 remove the ftuid reservoir cap. plate and diaphragm and siphon 0V1 some fluid. II acCfttlS 10 Ih.. piston head. I. too restricted wIttlthe caIIp8r In pIootI.

fflmOVII

the

caliper from ~. bracI<et (see Section 7). H the plSlons are difficult to puM back, allactl a

6 .1 c Remove the pad. from the ctllper

i<Jg the disc 1_ IIfl,lstratlon) . Insarl """ of the pad pins,

'*

g'''''''',

making SIn

~ pasMS

Ihmogh the hole In eact>

7

6.7 Fit _

....Im with en"OW pointing In the direction of disc fOtation

8.8a Install the peds _

il.6b . . then Insert th .. front pad pin

7- 10 Brakes, wheels and tyres 10 Operat. the Drag ~ _ .... 111.... to bring lhe pads Into contact WIth the dUIC Ct>ed< the OpenJlIOf1 eX the brak.I beIonIl'odong themot~.

~

Rear brake caliper removal,

overhaul

... ~

and installation

A I

Wamlng' If a calip« It>dIcates the need ,." a n overhaul (u~/1y dw

• to leaking fluid Or sticky opentlllMj, all old /)nih fluid sllould be flu , "ed from II.. 'I's tem, Also, du. ' c,.ated bl' tIt. brak. 51'slem ""I' conlaln

t".

albutOa, which II l1arm'u/lo your 1I_ Ith, Ne'tIlI' blow It out with cornptHHd aw and don' Inhale tanY alit. An approved fiIIetfng ""III ahould be worn ,.."." """"*/ng on !he braka .. 00 nol, under any clrcums tanc ...

usa pelml.um-bated solven t. to cl.a n brake ~rt.. U.. the speclfle,d c.." braka fluid, dediuted brag cJeener tr ......,III.-d alcohol only, " dNcrfbed.

Removsl

1*1, then hook u...-..:I eX tho 1*1 apring oodIr tho pin, milking lUre the ~ outer tabs of Iho spring point In the dWection of nom'4II "'-' ~ Iho ott. 1*1 It..pring.-..:l 1!IO!he!

rotation IMellus1nltionl.l

pm. ~ down on

lhe pin 1;11 0_ II (I •• UlultraUon) , Fit the retaining clips (s •• illustration) , Install th. caIper _ ( _ ....t..-llonl. 9 Top up lhe masl ... cylinder reservoir II nec:.ury(aMDlllyp..t>deJc/IecQ},

1 II the cal iper II being overhauled. rernov. the blake pads (aM Section 6). If the caiper II only being dlsplac«l g ............. they mlat be ~ with Note: It )IOU .... pJaMlng fa ~ the cilltpet .nd don't IIIw a source 01 ~ eN fa blow out /lie P/S!ons, }us! loosen /lie banjo bolt at fflis Jtage ffnd ratlgllten it lighl/I'. Th{I blk.'. hydraulIC 5J"1I..." can lIMn ~ UJed to ~ the piJtons out 0I111e body one. lhe pads 1IfI... beeI'I temOIIed. o.scoonect the hoM once Ifle pistons have been 5uffic/e(llty

new.,..,.

.

..-..

3 Unscrew Ilia cehper mountIng botts, and alode the cellpel' oft the dISC (1M .... tretionsj

Overhaul

7':' Unscrew the bottIo IaoTOwed) , • •

7.3b .,' and Iflde the celipet ott the disc

t'"

e~I ...I
.. elMn the

Brakes, wheels and tyres 7 a 11 ~ the seals (_ below) from the bore of the d~ piston. II'4n IWiraI;IIt the piston .nd bkIck ~ I,IIing the wood. Now cIIpIKe the p"'ton "om the othelr _ .... ng the ~ method_ R"""""" 11M wood and both pistons. Marl< etch PISton " - : j and caliper body with t !eH to -.... IIIIt the; pilton. can be ~ to tt.. ongonaI_ on..-nbly If the COfI\pI'-.sed ... ....u.od • UNd. dncI 11M _ Wtto the ftllid ~ to lor<:e the pislon OIl! of 11M body. lIM only low presao.n to_lIM poston out H 11M ... ~ is 100 high .rid the PIIIon II forced out. 11M cab!*, aodIor ~ton may be damIged. Wam/n,,: In ..... P""')'OIN" ~ In front of IhI piston In ... ttt.-..pl 10 CIIte" or prolKt It .."." IppIying comprHHd air, as -""'" inJurr cooidrNu/t. Clutlon: 00 not Iry to remove thl pis ron. by ~ thMn oul, or by u.Jng p/IIr3 01" .",.ot_(Jt$>L

"*"""

.f.\ L1.l.

I lJsn;j • wooden 01 .,IC dU~1

toot. _

the

.., I, "om HII clIl'per DOr... (s_

Illusttallon 3.11. Dosc:ard them .. new OllIS muIt be laid on ....~ H • meIIf tool II being laid, ~ grMt C8Je not to dImIige 11M

caIoper_.

-..,

1 A"""",. and dlSClfd the pislOl' . . . . In the

• ClNn lhe; p"'Ions lind ~ w,th clean bfaIo. nuid or ,he; ~ifild type. 11 comprwt«! ... Is IMlIJabil. USI ~ to 1Iry!hol pari. thoroughly {mllka ........ 11'1 l ilt..-.d arid

........

CeutJon: Do nol, uttdIt" ...,. o::/tc<.I<munc.e. be chlcl

*"'"

tnkIltuId .nd instailthem '" their grOOVeS In

(pn-~)

~--

.yslt'" .. deIo1bId in SIctlon I I. " "remoVld. Inslall lhe; brakl pads 1_ S.ction 2). lit the " ' - Into ib clamp ~

-

12 Lubrlclll IhI po.lonl with clean brakl nuid arid InItaIIthem cIoMo:!-
......

Installation

lhe pistons I little W8)I back inlc the cellper using har"KI praIIUrl or • piece of wood .......... Slide the cIIIoper onto 11M br_ diac:. making ...... 11M pads -.1 ~ -"her slOe 01 the disc ~ tilly werarl·t.fII'JlCIved ( _ MIu'trllion 1.3b1. 14 Instill the caliper mount.ng boll •. and ~ them 10 the tOlqUl ""'""'CI1PICifiId " t 3 Push

the

bIg,nnmg

of

1M

Cl\lptlr

1_

Mlultralionl) . 1$ If d".ched. COfIr"llCI the bralcl hose to !hi caIol*'. malung ...... 11 Is corNOCtIy routed rour"KI the torque ..... _ Use new SNIt"" washers on 11th slIM of !hi .non. .nd IIign thl hCSl as noted on remo~.1 111111 illustration 7.2b ). Tlght." the b .... jc bolt to the torqUI Mttong spec/fIId at !hi bIginoing of thl Chapter, Top up the ma" .. cyI.nder .~ with DOT 4 brl"" nuld ( _ DalIJ'

chec:ks) and bleed thl hydraulIC

"*'

-. -.

necessary ( _ Mlustrallon 1.2801. 11 Chick for IfIaka and thoroughly I ..t the _,,"'" o r the brakl batora rMling the

8 Rear brake disc ilspectlon, removal and iosta/Iation

~ ~ ~

Inspection 1 Refer to 5«:tion • 01 lhis Chapt ... notong thai 11M dIeI gsuge .r.oukI be aIIEh1d 10 11M

Removal

2 RImoYIIhI.--whIII ( _ SIctlon IS). :) MlrlI the rell1ioNhlp 01 tl\l dlec 10 tl\l wheel ..a It Can be InSI.11ad In 1111 ... me po,ltlon. Unacrew tl\l dlac retllnlng belts , IooMr*IQ them -...... .nd • HtIe II I time In I criIs-c:rou pattern to ",Old dIStortIng 11M dIIc • .nd _ 11M dIsC ( _ iIIustr.tIon).

7

7- 12 Brakes, wheels and tyres

Installation 4 InaUllithe disc on \he wheel with Its l1I&"ked -'de I""ng aut, rulgt'Ong the p"""""'s/y applied matct\marl(& r~ you're NlnsUllllng the original

-,.

5 CINn lhe IhrNdI of the dis<:: mounting bo/tt, apply. SUI~ non-~ tr.r..d locking compound. In,t.1I the bOlt, WId tight., them ~ WId • Ilttlto at I tirM In

t'-'

• enll-eross pattern to th. torQUfI H1I11\(1 S!)Kllled at the beginning of lhe Chapillf, c.... 011 .a gr_1fom It. tnke disc: using acelone or bnlke system dilliner. If a new bnlka disc has bIlWIlnstalled. rlllllOYtl any proteetlYa eoating Ifom "- working IlA1aeea. e Instal It. ' SactIon 15). 7 Operata It. brsk, peeI.1 ,",verallim.. to bring I/le pads inlo eonlliel wlth the dis.:, Chack the operation 01 Ihe brake earalully bIIortI rk:Mg the motoreyela.

whMI_

9 Rear brake master cylinder - ~ removal, overhaul and ~

Installation

~

I It the mall ... cylinder IIlHklng fluid. or It the ....... does not prod~ , firm leel whe<1 ItIa ttrake ;. applied. and ~ It. brill..

does not help ( _ Seelion II). and the hydraulic hose II In good condition. than maSIer cylirtcW oYIlrttaui is recorn.........oed. 2 Belore di....-nbling the mast. cylinder. reed Ihrough the anln procedure WId makIl aura llIaI you hIlv. the correct rebuild kit. Also. you will nMd _ new DOT • brllklt nulI»IIrs w~ wor/(lng 011

_..

1hIl17lll..'ltet"~.

DI. ." ....b/y. 0""".1.1/ and m.,'''- cyl/ndw mutt ~ 110M 1rI. IPOt,.ssly elNn wo,*" .,... '0 II.wHd eont.mlnlllion lind po.aIbIot flli/u .. of " .. brllk, /lydrllullc S)'lllm C.ulion:

,....embly of,,..

tin",

Removal

3 Remoye the rlgnt-lland aida eoy.. (yZFlOOOR), side COI.Ilr1I (YZF75OR) 01_1 cowing (YZF75OSP) (_ Chapter 8).

• Ramo ... the ..... HCUring lhe

mlllt.

cylinder fluid ........ oIr 10 Ihe Ir...... Ihan r,,"ove Ihe ' ...... olr c.p clamp (yZF750R and SP only). cap, diaphragm plllte ,nd diaphragm and PD" the fIutd Into a coni.... 1_ Ulustmlon). ~ the ct.mp MCUMg

I.e RemO\
the rMI!IrVOir hoM to the union on the mast. cyIW>der and doMach the hose. being prepared to calCh WI)' ...-ldual ftuid ( _ Ulu,tratlon). 5 Unscrew Iha bnlke hoM btnlO bolt and separata lhe bnlka hostt from tl"4 mISter cylindar. nollng Its II.Iignmanl I_ iIIustmIon). ~ the two MIllIng wuhan; lIS they mUit be repIaoed wIttt new OMS. WrllP the wid 01 tl"4 hoM In , cINn rag and suspend tha hoH In an uprlghl ~It ~ or bend It down carefully and pIIce 11"4 open and In a clNn container. The objactlYII II to preY ... t excenIYe loss 01 brllkl fluid. nuld spills .nd sysIIlm oontIlmInation. e RIlmo'III. IhII split 1*"1 .nd wast. from the cl""is pin ....ur1ng Ihe ~kll ped,l 10 tl"4 maSler eytlnclar pu-'t'od I _ l"u II,.tlon). Withd"w Iha clavltt pin .nd .. paralll tha pedal from the puaIYod. 0i8catd tl"4 apI~ pin

as a.-one must be """"'.

~ Ihe two bolts ......,mg the mastlll" eyIindIII" to the Iootr.sl brKkel and rernove the ........ ey'h:Ier I - IIuWatIonI

7

Overhaul 8 If required. mark the position 01 tl"4 elevis k>cknul on the pulhrod. Ih ... liseken lhot Ioclmul WId ttvNd the cIeII\s 011 the pushrod

1_ llluatm1on).

Brakes, wheels and tyres 7- 13

I ~ the rut.t.r dull boot from the bue 01 the mast. cylinder to reYNI the puehrod ret.ining arcIip t_ Illustration) 10 o.p.... tile puahroo and. using elrcUp pll.,.., r.move tile elrcllp {,.. lIIult' allonl , SlIde OUI 1M piston IISH!'I'IbIy rod opring 1_ ",.....,110"'1. II they _ d,lfIeoIt to remove, ~ low t:na
00fTIP'--,,,

....

PI'"'

elution: Do no!' ~ any ~wm"nCN, u•• • JMtroieum-bl.ed .oIvent to cleln _ . pili.. It compt'NIed ' " Is ...~

.... " to dry the perU thorough!)' (mllf. wtd un/utIrieIted). 12 Cheek the mUI. c)'hl'lder bore lor 00tf0Ii0n. ~ rockI M'Id _ 1TIIIfIq. II the I>ICHUtY m"lUring ItqU'pmerlt I, .vaUabltl, compare the diamflt. of the bore to that g/vtIn In !I>e $pec/fIeIttlonl SectIon of this Chapt•. II damage lei ... ~t, l he m •• t. c:yIInOer mu.t be ~ with • _ 0I"III. II Ihe cylinder ;. In poor condiIion, IIWl

.... If.. _

_I<

Ihel;lllipersh<:o.*:lbe~.weI,

13 lnapKI IM.-voIr " ' - lor cracb or

aptlt, and ~eee It with , new one II .-...y. II required, puI the union ""'" Ihe e~lnder. Discard th. bush as a new ITIUII be usad. 11 The dUI' boot. c"c~P. piston IlIHfnbIy M'Id IIPMII .. Inc:It.Ic*IIn Ihe .-.buIld kit. lIM all 04 the . - part" regan:l1esa 01 the appaNnl condition of the old ...... Fit !hem accC«llng 10 the itlyout 01 the old PIston

ma"", 0I"III

-.

Fit the ,pring In 'h. mU1er c~iOO ... .a Ihat Ita lapwed ..... I.,.. the piston. HI Lubflceta the piston ....ooty with cIMn bnke IUd. Fit the UI8fnbIy Imo the mut. cyllAder, makn-,g ..... It Is the COO1'IICI wly f'CII,nI. Mab ..... the \IpI on tIw alp do no! turn InIide out ..m.n they . . IIIIpped into Ihe 1~

-.

17 I..."" and depr ... the puI/lrod. tt..1 fit • ....... c~P. maI
11 tr.tIIIlhe I\IbbIr ~t booI. mekinO ...... the lip " _ted property In Ihe QrDOYI 1_

.......uon1·1II.

-. "

\I _ _ , fit • . - .--voir hc.a union

buth, thin puIh the union Into the m. .I .

20 "removed, Ihrud the davis IocI
Ins ta lla tion

2' FIt the mast. cylinder onto the tootraet tncI<et and tight. . ill mounllnQ boItI to the torqlHl ""ing lpecilled at lhe begl,,"~g 01 the ChIpt.... 1_ 1~"'I "IIon 0.7}. 22 Align the brake peeI.1 wilh lhe ma,I" cyIInd...- pustvod dIYII, tt.I dde In !hi cIIvII pill IIfId secure 11 uaIng • . - apIit pin, flOt IorgIoIting !hi ....... !Me IIustratIon 1.41 Z3 CorwIect!hl IQQ hoM brtO bolt 10 !hi mutl< cyIinOIIr, USIrIg a ....... SMIing wIIIher on IIICtI side 01 !hi banjo union. EnIura lhal the hose ill potIItoned 10 that ~ butt. . . . .t

lhe lug and Ilghlen Ih. bania bolt to lhe lP9Cilled lOfqlHl Mtling , .... IIIuItretIona 1.5l. :M On YUIOOOR modoIII, Install !hi fluid I'--.oit IIfId tighten Itt _ _ t_ -.-..;on OAII. On VZF750R M'Id SP modIII.. Icg\1I tIw --..or In poeIIian but do not fill ~ 10 the tncket ~ 01 1M cap~. &.uri th81 !hi hose II 00fI1IC11y routed, tt.I coorwct ~ 10 !hi ..-.ion on tIw,.... . cyIrdIr lind ..,... ~ _ the damp I.... tnu.1ratIon 1-4b1. Check Ilia! 1M hoM II HCU'e IIfId dImped 'I !he .--voir end II WIllI. " tIw dampe hIVe

-,'---

,--

'- ' Db MlStercytindlrcompc>nenti

,-, C>
4 PiIIcn -.bIy1lfld ~

5

~_unIon

, ",,"

Z5 f Ui the lluld .--voIr with . - DOT 4 Ink. lluid 1_ Dally p..rIdI)~) and ~ 1Iw 1yS1.... IoIIowIng the ptOOIdI.q In Section 1 t. On VZF750R ItId SP rnodeIa. on o:wnpIIlIon ""tat !he.--..or c.p dIoo:np ItId lighlen the.a.w, 2fI InsI.1I Ih. righl-kaOO lid. cover tyZFI OOOAI, ~ov.... tyZF75(JRI Of ...1

,Id,

cowling tyZF750SPi 1_ O\apttr ~I. 27 CIw:k trw op..-atIon 01 IN tnI<e Cll'eIuIy __ "'*'II IN moIlIIq'CiL

10 Brek4I hoMt. pIpn and I.II'IIona inspection and renewal

~

:t-. ~

Inspection , EI
and pipe condition ahouId be

checl<ed ~ and the ~ .-..-ed at the specIIIed Inl......., f8M Chapt.. 1), 2 Twist 'lid fl.x Ihe rubber hOI .. whU • looking for cr.ek" buto- and . . . .ng ~uid

I'" HI... tr.uonl. Cheek extra ca.-.lully around lhe ar ... w...... the holM cont>ICt brtO IIt1inga. as U - ... ootI'III'IOfl ..--b'hc.at.ill.n.

with Ihe

7

7- 14 Brakes, wheels and tyres

10.3 On VZFIDDDft models, cMdIlt1e condition of the ....1-' ~ on MCh front

'"""'

3 On YZFlOOOR mod.... ln~t tIM metal brake pipe on eaeh Ironl e.llper, and on aU rnodeb check tIM banjo union f1It,ngl connected to Ihl braka hoMI 1_ lBustmlonJ. II 11M pipe II dImIIgIod or I\IIt.,;! or cracl<ed, • ' - caliper must be lnIIllIIIed .. !he pipe II not available IIJ)fntely (though n would be worth checking wllh • braka or hydraulic hose/plpe lpeeillilt). It tha union fin lngs Ira rulted, lC"'tched or crac ked. fil new hoses.

Ren e wal 4 The brake lIoNs have banjo union finll'9l

on each and. eo- the aurroundlng _

wIIh

plenty of rags and UII8CI'eW the banjo bolt 1\ each end 01 lhe ho5e or pipe, ootlng III

alignment II.. Illul tratloni . F,.. tlla hole from any cllpe or guides and remoYI ~ . O"lclrd It. _ling wull_ on !he hole

.....

5 PositIon the _ hole, making an ~ lin'! twillt.,;! or otl\erwilla , trained, and lbut tIM lab on the hole union wilh the lug on the OOITIPO'*'I casmg, wt.w. ~. 0therwtM align the hole .. not.,;! on ...-noY1II, InItaIIhI hoee banjo bolts .-..g _ ...-ling WMhen; on bath __ oIlhI..nor.. 'fIItttan IhI ~ bolts to till lorq ... Hltlng apae/fI«I II \hi begoInning of this Chapter, Maka sura till tIOMI _ GOnlICtIy and IOUI.,;! cIMr ~

01 .. mcMng

0CItnfI0I1III'I

II Flush the old brake tIuId /rom the system, relitl with new DOT 4 brake "uld (SM o./Iy

IDA Ramo... !;he banjo bolt and IIp/lrata !;he hoM from the c.IIpar ; thIIfe Is I IIIIing w ........ on each side 01 !;he IIttIng

o--ridall;hacb) and bleed !he air /rom !hi Iystem 1_ Section 11). Ciw::I< the operation 01 till brakes Clte/ully balorl

~,ng

till

~"",".

5 Ramo... 11M I'teeIVoIr ClIP or co_, diaphragm plsla .nd d~m and aIowty jlt.mp the tnka ....... or pedal I few ~ ...-nt no _ bubtlIII CIr'I be . . , fIo.u-lg ~ from the "'*'- in the bottom of the ---*. 1hIa bleeds the _from IhI ....,.. cyIindIr and of !he .... looMIy I1IIIt !he .....,. c.p 0/ oo-ter. II Pull the dull ClIP 011 Ihe bleed YII/Ira 1_ l ........ tIon!, Attach _ and of !he daar WIyI or plastIC tubtng 10 Ihe bIaed v...... and sut>margll the othar and in Ihe brakl IIuid in the contIInar 1_ ilualratlon). 7 Ramove lhe rllHl"lOir CI9 or CO\Ier and cMc;k tIM IIuId ....... 00 nol .11ow lhe nuld ...... 10 drop below IhlIow.- mMt ct..oing IhI

.....-

8 ca._ully pump !hi braka ...... or pedal thr.. or lour 1,,,- and hold It ,n (front) or down (rMf) willie opening 1111 c.liper bleed vIM. wt... !hi Ya/Ya" openacI. brakl ftuid wlI !low out oIlhI caliper inlo Ihe dMr tubing IInCI Ihe laYer move towarcithe handlebar or the pedal wll mova down. " RelIghI"" Ina bleed valve. I'*' re4eeaII llle brake I.~er or pedl l gradUllly, Repeal the procesa uotll no ... bubblellllfl visible In !he braka ftuld laavlng 11M caliper, or H Ille nuid Is being changed unl,l naw Iluid I, coming out. Ind til. lav., or pedal ~ firm when Ipplled On completion. dlteonnact tha bleed'ng equ,pment. therl llght"" lila bleed Y...... to IhI torq ... Hlling lpeelll.,;!11 till beginning 01 the ChIpt.,. arid hatalllhllMt cap.

wi.

I Bleeding 1111 brakBS ill simply the proc8SS of r....avIng all the Ilr bubbles from the brake fluid "$&NoI~, the hcr-utl and the brake calipers. Bleeding I.. nOC8Sllary whenever a braka Iystem hyd rauUc connection I, Ioollenlcl, when _ component or noM ill replaced or renewed, or when tile master cylinder or caliper Is CMlfhauIed. leaks in Ihe system nwy Moo dow _to enter, but ~ brake ftuid wlI ........... !hair ~ and wwn you 01 Ihe...:l lor repair. 2 To bIaed till brakes. you will need :sorn. _ OOT. DnIke 1Iuid. _length 01 ~ w.yt or pintle tubing, • lIm.n container partially fiIleO with ""-' tnka 1IuicI. _ raga .nd • to lillhe brake caliper ~ ~ 3 CoY.. tIM fuel t.nk and other ""nled ~,. to prll'l"'" damage In the ~ ~ bnokalluid illpillad. • When ~ Ihe ..... braI<. •• remove the right-hand .,da cover (YZFlOOOR). aida

"*"'*

-.

cover. (YZF75OR)or _

~

(YZF75OSP)

( _ Cn.pler 8) lor ac.::eas to !he "uld

10 Install till dl.phragm and cap or COy .. -ooIy. -..1pe up....,. ~ braka IIuicI and c:t-=I< the..-.ln l'fIIarn tar IaIks.

HI ~ •

II 11'1 not poaJbIa 10 ptVdtJca • firm 'HI 10 the ,....., or pedal Iha fluid mq be .araled. hI the brlka fluid

In thfI ~ t... • 'ablllsa f(N a ,.. houI1t and Ihan rapNt the proc«lure ... han tha tiny bubtn.a In the .,.tam ha~1 Mltladout.

12 Wheel. Inspection and repair

It.&. &aka caliper blHd VI'''' (1ITOwed) - typIcaIa..mpll ahown

11.1Ib To bIaed the brakel, you need I ~,a ahor1 -.ctIon of clear tubing, and. clnr contIin ... hIIH·filled whn braka

"""

t In ortIer 10 c.-ry out I proper Inspection 01 the wheals, ~ iIIl'oICII$If)' to .... pport the blk. upright ao thll 11M whaal being Inspected I, raised 011 the groond. PoaltkIn the motorcycle on In auxiliary lIand. Claan tIM wheel. thoroughly to remove ""-'CI and din thai may Interfere with till Inspeetlon procadu", or mlSk da/acl•. Mlka I g_al Che;ck 01 lhe wheel, (1M Cha.pter 1) and tyrII (1M DeJJy (prHda)e:tt.cI
Brakes, wheels and tyres 7- 15 2 "tt.,.h • dial gluga to lhe lone. or lhe swWlQann ..-.d poeitIon its tip .pnst !he .", of !he rim !_ Illustration) SpII'\ tI1e wheel ~owly and check Ihe axial (side-Io-akla) runoul 01 !he rim. In oroer 10 aco.nle/y check r&d,aI (OUI 01 round) runout with the dill gauge, the wheel WOtJkj hi... to be removed lrom lhe mlK:hlna. and lila lyra hom lhe wheel With !he"", cIarnpad In a \iIea..-.d the dial gIIuga posIIlOOad 00 lhe lop of the rim. the wheel can be rotMOId to check !he na'lOl"3 An a ..ler. Ihough ~~hlly lass accurala. method Is to Bllach • stit! wtre point.. to !he fort< Of Iha .-.garm and pealiloo the WId a fnIIction CI an Inc:I'I fn>m !he wheel !'M*a !he ~ and ry.a join). II !he wnaeI is I~. the dislance from Iha poinler Ie Ihe rim will be constant as the wheel Ie
-.

.. ,.". wheals Ihould alao be vlwally inlpectad lor crw;:I
-""'"

13 WhH6s -

1 _

~ofthe"""""~lNybe to • cod
lork yokes. ean cause slrang. and ~.lbIy aerIou, handling problem,. II tha f'sma O. yok.a ... II fatAl repair by I ffamoI specialist Of repIac::_t with new pwtl _ the ooty

".........

2 To ch.,;k tha .I~nment yoo wil l need 811 ISslStant, I langll'l of string Of a parr.ctly 5Uaigh1 piaca of wood and I ""-. "pIOO\b bob er Olher luilible weight will ,lao be ""luIrOld.

3 In OfIMf 10 maka I proper cheek of lhe """"" ~ Is nacwaary te wpport the bikl In

It 111M front-to-back alignment is comet. !he whaItI; -'II mwy be 0l.Il 01 ~~. 10 Uling • plumb bob. er other .... It.ab!e weight. -.d a length of string. checIt !hoi __ wheal Ie maka SU'a H I, Var1lcaL Te do Ihls, hokj the .hing IIgIImt !he tyN ~ III1d allow IN waIghC Ie sartIa just on !he floor. _ I.... string baCh IN upper ..-.d

""*

t_

lower Iyro sidewall' and I. parle<:tIy ,Iraighl. Iha .......... is vertical. If It Is not. place Ihln lTIder ...,rII the

"'**' _lag 01 IN - . ; M•. 11 Once !he __ wheelia -'Ic;aI. d-'<

fronl WhHI In I.... llame m.nn.... If bolh ara nol parfactly vertical. I.... !r.me and/or major auspanalon componar1l• • r.

wh""

12.2 Check the whaellor radllol (out-ofround) runout (A) and axial (ala-to-side) ~~I

an uprighl pceitIoo. using an auxiliary stand. MIISu,. Ihl width 01 both ty," al thai' wldMl polnl.. Sub lract Iha small« ~ from !he larger ~emam. than dMdoe lhe ditIaralca by two. The res..I! II tha amoonl 01 elfal Ihal ahoold exlll bat......,..., the f'ont aod ...' Iy," 00 bolh

-...

. . " a string Is used ......... )'COS ~ Iw;okI one end of h about l\a1fV;ay bat ....... lhe fleer -.d the . - axle. louching the ,_lIidewali 01

"...

II Run \he' other end elf \he' string Iorw..:I and P'J" ~ tight .a lhai H II rooghIy paraIaI te !he fleer (sea IWustration)_ Slowly bring the string into COI'
-

--.,.. --,"""-IMotoQMl _ _

......

~\.111C8 from lhe from be ~I on bOth sldes. ptall\oully meollOOad. • perfeclly str.ght IwIgIh of wood Of metal bIr mwy be ....b.titutad fer the slIlng 'HI Hlu.tratlonj .

the motorcycle. The

eyre Iidew8II to the .Iring sIIcuId

1.. .

The~lIlhe_.

I If IN diI\.anca ~ !he stmg -.d ryr., II gr. .t .. on one side. or if lhe ............. appears to be cocked, rale< 10 Chapter I. Sectien 1 .Old check Ihll lhe eh.ln edjuII'" matklngs QC)Inc;ide on aach aida e f the

-

-----

_ . , . . ...... 1Mo

.......

7

...""'-

13.1 WMeI alignment cheek using a

7- 16 Brakes, wheels and tyres

14 From wheeIremoval and instaUatlOl1

Removal 1 RWI'IOYtt the lower taMIng (see Chapt... 8).

N the motorcycle on an auxJU.y lland JII\d I Upport It under the e . ankel.. 10 HIlI Ih_ t.onl wheel is offlhe g.O<Jnd . AlwIYs make IUfe the motorcycle .. property .... ppOrI... 2 OllplllCfl t lMo !rool brake eiliperl (aee SectIon 3!. Support the ~ with I piece 01 wn or a bungM c:ord 10 ttwrot no " ' - ' i5 pIa<;ed on the hydraulic 1"10_. There .. no ....-d to dlseonne<:t 11M I\oHa /.om 11M caIIpera. ~a: Do !'IOf ope.-ale fIIIlrooI bnIte ........ wlfh fill c:arpws rfIt7'IO'Ved. 3 UnlJCrew tha knurled ring Heuring the ~ ... cable to the drtve g..- .... Iog a pair 0/ pll .... and de ta c h tha cabla tlee

5 Support the wheel. ltoen withdraw the axle from tha right-hand l-kIe fs . . lIIu.tratlon) . Ca.e/ully low ... the wheellrom b&tw.... the /orb, noting how !hi ~er dIM gear local. . IQIInIt the lOOt. Use a drtIt to drive out the axle " ~. 8 Remo". tha .~ ... /rom 1Ila I1oght-1\and !Iidoa of the wheel JII\d the apeedorTwIer drIYa gear /rom the ten·hand tide, noting how !hay fit 1_ nlustrallonl ). Caulion: Don't lay Ilia 10'11 . .1 down and allow It to .... on a dl.e - the dlK cfWld becoma warped. Sat fha wh_1 on wood bJoch aD I'" d'-<: doesn't I UppOrt fila W1Hght 01 the ",hili, or t _ If .."..;oJIL 7 ChedI!hI axle lor ~ DV roIIog n on a 11M ...-1_ aud'lu a piece 01 plate gIau (fifst wipe 011 II old grease and remoYI any corrosion ....Iog II... amery cloth!. II lhe eq uipment I, IVlnab l•. placllih. ul. In Vblocks Ind c hlJCk for runout using. di l l gauge." the axil It bent , rnplace ~ with a new

Mlultnotton!. of On li!1of -on YZF750R and SP model., ale<;kan the axle damp bolt on the bottom of the left-hind 100<. On all modeII. lleckan the ull elamp boh on the bottom 11M righthand lork, tt..1 unllenw the ull 1_ ....tratlon).

o.

8 Chid< the condition of the wheel f - SoIction 16).

Install.tlon

g._

~.

10 \hi wtIMI sp""', !hI1ipa 01 the IIfI'II'III . . . . and to the

• Apply lithium baNd

~er d ...... gMt. Altn. spaur InIO the rlghl·hand Ilde 01 lhe wheel 1_ 1• •BaI. Fit the drtva gear into the

-...m.tIon

lilt-hand lod •• making au .. the drivlI pillt. t~ locals In the lioii f_ 111...watton! 10 Manoeuvre the wtoMIlnto position. API*f I thin coat of gr-. to the Ilde 11 UII the wheel Inlo placa balw- , the forks. making . . . the fPIC* and driV'II gear .sma,n In POS'llon. and Ihll the slot In the drlYa g.ar local.. " - the I.t> on the r..Ide 01 Iha fork 1 _ M..... ' .. Uon) Slide tile IXlot In /rom the ri!trt'hInd IIda and tighten ~ to the

'4.' Make .... the drM tabs tAl Ioca'teln the IIots (8)

Brakes, wheels and tyres 7·17

torqUI Mnong lpeel!illd at tile begInning of IIw Chapter (He IIlu.v.tIoM) Now togln ... IIw ..... cIJImp boll on the bottom of the IightI\a'Id IorIt to the specified tClrQl» setting ( _ illustration t •.•I,..-d on 1994-0<1 YZF750R Ind SP ~s "SO t'ght ... tile JaIt-hIIod dIrnp boll. ClfI VZF750A _ SP....,.,.1hIIt don't _ . circIp IiIIIId In the groove In the 1.11 Ilead, mlk' ,ura that tha groova I, vi$lbla II It Isn't, repeat tile Installation

........

12 lnatalthe brake ~ maJdo>g ..... the ~. I" squarely on Hch slda 01 tile dISCI

(11M SeclIOI'I 3). TIghten tile CIItper """-O'I!lno;J

bolls to tile ~ tcrqua MI\IIIg. t3 F~ tile ~er cable Into the drI-.. ~ and tight ... tI'Ie knuritd ring ...,,;urwIy 1_ 1I1uttrltlonl) Tlk, tha btkl 011 III ... xiIiaty 1\lIl(! ..-d Install U.. lower !awIng (Me ctwpter 81. t. Appty the front brakl I lew t..... to br\rIg tha pade back Into contact with tile dISCI. TIIl
1•. 131 l....nltlacabla. barwaen 1hI.....na.I _

tile swinpm, &IppOf1

tile wh~ then wilt\draw the .. ~ "ong WIth the 0 _ adluttment poIJtion mark. Ind tow. the wIIMI to tile ground, bring",!! u..

1•. I3b ... MId tlghl.., _

ring HCuraty

c.,.;p. tncI<eI with It(_~. 5 Diserlg8(IIIIIw chain from 1tla eprockaIend """"" tile wtIaeI from _ !hi swlnglrm erIds (_1IUtIratIOn 15.101.

""'*

115 Clleck for CQl'rect opertlHon of thl front brake bIItora riding tile ~,

15 Rear wheelremoval and Wistallatioo

Removal 1 Suppon tile motOtcycle HCtJre/y In an upright iX*\lIIn '*"II ., ~ stand 2 Dilplace tha relr braka cahpeor (IH Saclton 7). Make ..... a no IS pIICad on ilia hydraulic hoM. Thera Is no _ to dl~t the I'-. from tile caliper. Nota Da no/ I)pefIIII the braka pedal wllh the

,tr""

aJJipar~,

:) SIed<en the 1Id~1. locknut on ucII ...sa of the -.g.m. tt.. tum tile -'lUSt. . In to pr~ IOmI Ilac~ In lha chlin (I . . Ylustrlllonl Whara ~ttad, ...""....tl\e spI~ pin from 1tla end of the ...., ~1tla ..... nut and r _ the _at- (_ Hlultnllonl Aart>ow 11M ~mant paa/l1OI'I marl<er from tI'Ie lelt-herld Iida {_lnustraUonj, • Noll how ilia caliper brllCket local..

7

!5.k ... Ind ramOVltt.. position mlrt<ar

7· 18 Brakes, wheels and tyres

Caution.' 00 not lay th. wh..t down and IIIIow If to ,.., on !he dIK or !he 6p1t>C1\'et"..,. C04JJd to.com. w~ s.t!he ...,..., on wood bIodia ... !he ...., or !he 6p1t>C1\'.t dootan'f support th .....lflll of the wh..t. 00 lIot opera'. 'h. brat. ~I wHh 'M

--

6 Check the ule lor .tnIIghtr>Ms by ron-.g ~ on • flat torI_ tueh as • piece 01 plat" glas. (fitst wipe oil IJI old g r _ and r lKTlo~ any corrosion u,'ng II .... emery cloth). If the equipment II Ivsilsbl•. place the axl, In Vblockl and c~k for rvnout uslng • dial ~. II the.,.,. It replace it with s.-

*'.

~

7 Remov. IhtI toIl,r Irom INCh sillf! of t~ wheel. noting which lits wll..... ( _ lIIustrltlon.) CMck the condition 01 the gtMM

Section

__

181.

and

wheel beerings ( _

In. tall.tlon

"*"-. through /rom the right-Nncl __ J-

6 JoWy. IhII'I coat oIliIhium based ~ 10 the IIpe 01 MCh gr_ MIll. and also to the

IIlul trlltJoo 15....). Maka sur. It pe.... through the call!- brackOlt. Aign the fin on the uJe ~ ~ the raiud Me\IOfIf, on

coli .... and the &de. Slide the right-hend Idj ... lfMnt ~illOn """".... onlo the 1ll
..-.

10 Eng. the drlvil chain with the sprocket 1_ Mh,rstr,IIon). lilt the wheel IntO poIitIon, bringing the ~Iper bracket witll It. mIIklng ..... it iocet" correctly between the wheel and the .wingarm (see lIIustnotJoo 15.4b). Melle ..... the coIIotIllIII\IIIn in ~. 11 SlkM the &de. with the adjustment

lhe adjustment matlt.... ( _ lIIu.tration) Cheek IlIlt ~ing III comICtly aligned. then lit I,.,. 11I1t-h""d adjustment pasot"", marQr with the 'FWD' marlr. at the front (_ IHultrltlon) . Fit the weshw and the ule nvt ( _ IIIu'trlllIon). 12 Adju,t t~ chain slack n described In ChsPI ... I, th ... t~lItlln t~ ul. nut to Ihe torqua senlng specilled at 11\11 beginn ing of Ih' ChapUti' (•• e lIIullr. tion). Wiler. IppI~. fit a . - spil pin into \he hole In till and of the ule - it the hole Is notllligrlld with ibis In the nut. light"" till nut unt~ \holy eIIgn - do not tIecken the nut. 13 IIWtaII till brake,...;p., maQlg l i n the 1** lit aq---'Y on eech side of the diIIC ~

-"

14 0pIIretlI the bnIkoo pedeI-.I _ 10 bring the pad. Into contact with the disc. CIlICk the operetion 01 the . - brake c:aoefuIy ~ riding the bike.

16 WhHl bearingsremoval. inspection and installation

Front wheel bearings

--..

Nol.: AlWays ntne ... the wheel bHrlt!g1: In ,.,., ,.....,.. indMdtJeHy. Al'Oid using s high ~a-wonlhe_t..1ng_ .

1 Remowthe wheel (see SectIon 14).

15.110 ... IMn

m tIM washer end nul

15.12 TIghten tIM . . nut 10 tIM ~

''''''''''

Brakes, wheels and tyres 7-1 9

111.3 Lev .... out the grease .eal on...:h

""

16.48 . .. \hen lev .... out the re tainer plate kom the left-hand side.

16.41> ..• and remove the drive plata

18.5a Knock out the bearings using I

16.5b ... IocaUng it as shown

2 Set the wt)eej 00 bIocI<s SO as rIOl 10 allow the weighl of the ....tleeIlo resl on eitt." brake disc:. 3 Lever oul lhe g ' _ seal 00 each side of Ihe whool uaing a la'ge Ilat-bladed screw driver. taking care rIOt 10 damage!he ~m (_

illustration). Discard tile

~eals

If they are

damaged or deteriorated.

~ _

HIN

Position " piece of wood lIfPimt !he wheel to pre«ent 'ha sc~dr/~er s ha '" damaging il wha" 'e~erlng the seal out.

9""'''''

dtilt . 4 Remove the retaIner pial' from the left-

ham! side 01 the wheel am! remove Ihe speedomet", d,lve plata, not ing how ~ filS (.... Inustmtlon.j.

5 Using I metal ,ad (preferably e bf8ss drift punch) Inserted Iflrough the centte 01 the one ""a~ng. tap evenly .roum!11le Inner race of lhe other bearing 10 drive ~ from the hub (.... lIIus tratlon.). The bearing spacer will also com.out. 6 Lay the wheel on its olt - side so that the remaining bewing faces down. Dw Ihem dry with compreased ",r (don't"" the bearing!I!
"the

HINT ~ '.

Refer 10 Tools and Worlfshop Tips (Section 5) 'or mo ....

IntonnatJon about-.;"p.

6 Hold the oute< race of Ih .. beanng and fOtate the Inner race - If Ih .. bearing d08$l1't lum s moothly. h89 rough spotS Or Is noisy. replace II with a new one. a If the bearing is good and can be ,..........d. wash ~ In solvent onee again and dry il. Ihen pack the bearing Wllh ,thium based {ll"ease. 10 Thoroughly clean the hub area 01 the wheel. Install Ihe right-hand bå InlO lIS recess in the hub. with the marked or """~ !IIde facing outwards. Using the old bearing (rt new ones are being fittedl. a bearing drtver or a sode! large lIOOugh 10 coni act the oule, race 01 the bearing. drive It in un! il ii's complelely sealed ( _ IlIu"ralton).

11 Tum the wheI!j over and IflStaJl the bearing o.pacer. DrI\IfI the tell-hand bearing Imo place

as described 1ll><wfI. 12 F~ tha speedomeler drive plale Into the left-hand !IidI!I of the wheel, witf1 the drive tabs faclng out and aligning the flat tabs wilh the culouts in Ihe hub (see illustration 16.4b) Press the retainer plata onto thll driv. plate (see Illustration 16.4a). Apply a smf!8' of I~hium based gr&aS
7

7- 20 Brakes, wheels and tyres

...

11.13 u .mg. pi.,;:e 01 wood e nsu," the _

I ~ "ush with the rim

14 Clean of\' all grease from the brake discs USIng _one or bfak_ a)'Stem ~ tllen instal the wheel (.- Secbon ,.).

ReaT wheel bearlrrgs 15 Remowo tlMo.- wheel (-. s.:tIon 15). lJPtocktt eoupHng out of the wkHI. notIng IIow it fill. and ......,"" the rubb6r damperI 1_ NI...trMiona) 11 SellhewhMfonblocka.oasnottolloilow the wejght of tile wheel to ,est on Ihe brake disc. 17 Leve' o ut the g.ease seal on the rfghthand ,Id e of the wheel uaing I la.gl flet~.ded .e.-.wdrfv... , taking ca •• not to datTmge the rim of the hub (_ .... vr- Hint above) 1_ l......tIon) . CkIcat'd Ihe seal HIt

un the

it; ~

or o.tenoratad.

18 u.ng a metal n;wj ~ a briIss drift punc/'l) "'~ through the .:entr_ 01 the rlght·hand bearing, tap evenly around the lnoar oxa 01 the 1aIt-1wld beMng to drive ~ from the hub 1_ lltustl'lltions 11.5a and b)

-.

..._a

11.151> . .. and......,v.therubbardamper

The baaMg ~ wiI also corne out. It lay the whMI on Its oth..- $Ida.o n..t the

-

right-hand bearing laces down. Drive th. beating out of the wMet ""'ng the ...... technique _ 800Ye.

20 ReIer to Slape 110 9 aboYa IRI check the

21 TlIoroughly clNn IIIto hub araa 01 th. wf"ooaI. Fr.1 inl1an thelelt-hand bearfng fruo ~ .ac... in thl hub. wIth the marked Of ..aled 'Id. lacing outw ards. USing the old bearing PI new ones ar. being titled). a bea.lng drfver or • soc k. t large Itfloog h to oontllCl the 01.11... race of the bearfng, drM It In aquaraly until It's complet.1y seated I_ llus tration 18.10) 22 T...., the wheal over and Install the baMng

specar. Orfve the

r'9'rt-ltand $Ida ~

pIKe _ dascribad above.

into

AflfIIY a _

01 grease to the lips 01 the new g ..... _I. and ~ ~ onlO tlMo nghthand aide 01 the whMI, USIng e .... or ~

23

dnv .... a IUlllble socket or a Hat place of

wood 10 drive It mlo ~ It ~ 1_ Wkntntionl tI.l 2a and b and 8.131 24 Clean off all grease from I.... brake dilc

u.ong _one or brake system dMnar. FIt the lUbber ~ Into the wheel, than InMaII the coupling usembly 1_ .....In~ 18.151> and e). Inslallthe wheal lsee Secbon 15).

aprocktt

Sprocke t coupling bea ring 2tI Remove the .aa. wheal (see Section t5) . Ufl the , prock. t coupling out of tha wh"" noting how It fill ( _ illu,tration 111.15&) 21 USIng I large flat-bladed !IOCfawd"".......... out the grNse ""I from the out,id. o f tha coupling, taking care not to damage the rim of tile eouphng (_ HI~" Hint .bowe) 1_ lIultraUon) Dosca-d the MIll ~ It it; dIImagad Of daIarIoratad. Rarnova the specar from the ...... of the coupling bearing. not.ng whlctl WlY round It lils. l.IIIIng a SUItable toekat to drtvelt ouI from tha 0UISKIa If ~ is toglt! 1_

--I

'Z7 s....pport the coupling on bIocI<.s 01 wood and drove the baarfng oul from the tn~.

USIng a beanng d.iver or lOCket I'" l1Iuatrltlon) 28 Refer to Stept 7 to 9 aboV1Illnd check the ~~ng.

2t Thoroughly clea n th. belrl ng ""e.. In tha coupling then fil tlla bearing Into the outsld.oI the eoupllng. with the marf<ed or ...aIatj IkIIo lacing out. Using the old '-Ing a __ one it; baing fined). a beating ~ or • lOCket ~ .-.ough to oontact the 0\11... rae. of lIMo tJe.ing. drive it In until It I, compIaI:aIy M8ted 1_ illustration)

r"

Brakes, wheels and lyres 7- 21

18.30 Support the burIng . . shown wh
18.31. P ..... or drtv. the _

driving In the spacer

30 Fit t~ spacer Into the inside 01 the CO
damp«s(seeChapter6). 33 Clean off all grease !rom the bra ke dise using acetone "" brake system cIearler. F~ the sproc ket COen Insta ll t~ whe," (see Sectlon 15)

I Into the

coupling .

11 Tyree general infoonation and fining General Informa tion 1 The wIlMs litted on &11 models are designed to take tubel..,;s tyres only. lyre si zes are given In the Specifications" the begMklg 01 this cl\apter. 2 Ref... to II>e DIIlIy (pre-riOe) checks Iisled at the beglnnl"1l of this manual 10' tyre

-~

Fitting new tyres 3 When selecting new ~. ,efe< to the lyre inIonnBtion Iabet on the swhgarm and the lyre isled In the owneq handbook. EnSU'e

opt"'".

thet front and rear lyre ~ ere compatible. t!>e correct size and COffect speed ",ting; If necessary __ advice from. Y~ dealer "" lyre IItUng speciall$t (," illustration). 4 It Is recommended that tyrea are lrued by a motorcycle tyre sped",llst r",ther than altemptilld In the home workshop. This I, panlculaMy relevant In the case ol tUbele" tyre9 because the force r'9qulred to break the seal between the wIle
specialist conceml"9 tynt rapan

7

17.3 Common lyre aldawatl merklngs

.., Chapter 8 Bodywork Contents F~ II/Id body paneII- removal

and installation

FI'OOI~-_allII'ldln5tallation.

GeneralIn!ormatk)n .

1

Rear view rnIrrc:n - _ a I and Installation . Seato - remoYIII ....:Ilnataklion . W\ndstIIoeId - _ a I II/Id inst.....tIon ..

Degrees of difficulty

1 Generallnformatlon

this Ct"pter co ...,... the p
--.

operaUoOl on theM motO«:y<:l8s requl", tho lWTIO'VaI of tt. body parta, the procedures IIffI

grouped 11«, and r""'flld to from o,r~

In the caM 01 da'nIige to the body partS, ~ ......11y - . . y \0 ..."..,.... \I'MI brok..,

<XIn'IpCIIWII_~MwIth.IMW«:o'1.INId)

one.

n..

malerilllillel II'MI body parMoIa _ compoHd 01 dOHn'l IwId it""," 10 oon .....11or* ~ lechnlq..-. n.er. _ how~. _ aI>OpC thai ~liH In 'plasllc wllldi"ll·. 110 ~ may be wortl>whu. Meki'>g\he ~ 01 one 01 tt.M speciaIista befOl1l consigning an I Xpensiv. component 10 thoI bin. When anamptlng 10.emove any body panel. flrsl.cudy H~. noting any lasten&fS and lnoclalad m llogl. 10 be lufI 0 1 ,etumlng

~

to Its corr.c'I pI..::e on InsUIIIItion.

_1~.maka....-e'fO'Jl"'_.

In_~tt.llidol.,,_wllbol

on '*'<110 install it.

requftd ~ .....oWog peneIs. 10 help avoid the MI< oj damage 10 PII,ntwork. 0nc40 the e'o'kIwlt IW.,.,.,. """. been ,,""o...,;!, try to wiIMraw lIMo I*lII u ~ but 00 NOT F~ IT - H ~ wII root ~. check thaI .. ,.., ....... h .... been removed and try again. Wh«'to • panel engageI aoott>er by r'I'MNIIlI 01 I .~, boo ca'-'u4 not 10 break the tab or ~. mating slot or to damage the painlwOtk. Remember tt.t. ' - ~ 01 ~ ~ thl. 'I~ "WI Y"" • lot ot money In ~ btoI<.-.lM"ng"..-1 WIMn inIUIIIng • body panel, first SI~ ~ cIoMty. noting ..-.y and~.,;j 1ittir9........,.,...; with it, toto. ..... oIl'IIlunw1g ~ to .. 00tI'.cI pIIce. ChecI< """ .. ,.,.......... In good condmon, InclJdIng .. trim null or clips and dampinglrubbef mounta; any of tt_ must be ~ with new one. w rlully before the panel Is .......",bl-.;l. CtlKk also INI all moun~ng brackets are atralght and repair or . - - tMm II necHUry before attempting 10 1n11alllhe

Tigt'lI.., IIIe 11"-' HCUra/y. bol be caraf\.II not 10 OYeI1lghIM any oIlham 01' \he panaI may breal< (not always immediately) dua

wi.

'115_

pan~.

Wn........t.nee was required to

r---------------~~

10 \he ..........., 11teIS.

2 _removal and iflStallation

Remov.1

mod.....

I On YZf150A 10 ,.....,... I". o-t \he ignition ~ into \he _ lock located bIIIbw \he 1liI1ighI• .-.d \U'n H cIockwiM 10 unlock thoI _ I (1M ~ . LlfI. up the t.cI< of thoI _.-.d ~

..c.

df1lw h _rwardl. notIng now lha hook, Ioca" undaf the pegs (I. . Ulult.-.t1on). To .amovl Ilia Mal. firsl ,emovl 1M passengar Mil. Now pull Ihl fllNN 1."..back. th.., lilt up Ihe back 01 1M _I and df1Iw It rearward •. noting how the Ulbf; tox:.II IJfIO&f tha platl (1M Mlulltrations) .

rid.',

,-~--------~

__

~__,

8 2..1b ... noting howtha

hooII'IAI~

_ _ pe{II(8)

8- 2 Bodywork

2 On YZF750SP ~., _ tIM _I cowling ( _ Slctlon 3), " required, _ tIM 1Cr&wS Heuring the seat 10 lhe cowlillg and HPMIte t'-1. 3 On VZFl000R~, to remove the rIOer'. Mal, insef1 tha !grutlon key inlO the _ I lOck Iocaled In Iha 1e!t-1\Ind sI<;Ie QOYer, IlJ1d tum ~ okx:kwIIa to unlock Ihe leal 1 _ lIIustn1tJon), Uti l>P lila back 01 the _ t and draw ~ ~ noting how the tab locales rna the tank IncMt lsea lIu.trMIon) . To AIfIIOYeIha pasaeogar _I, tnt remove the ric*'. _I. Now 11ft up the front oIlha ~ seallII"d draw llorwa'dl, no*Ig how ~ Ioo;tIIe!:I QfIIO Iha ~'*" Iha frontlll"d how l *'Is .,....,.Iha tab ,. Iha DIICk 1_ .....-ationJ.

......

,.

Inst. lI. tlon of InslaJlation II lila _ _ of I'<<00II8I.

3 Fairing and body paneIs removal and InstaJiation

by lurnlng lhem enl'-clockwIH 1_ IIIIMtratIon). 3 UnKIYN tha two bolts llIId the screw on MCtl aide and the lCrew joining lila middle ..ctlon t_ Illu.trallon). Carefully draw Iha aide ~ apa'1 ,llhe lronl and middle, !hen draw Ih. usambly back oil the bike (. ..

IIlustratloo) .

VZF750R models SkMco... _

--.

I Aamcwa Iha _II (sw Section 2). The aida

COVert . , .

remoll«l u an assembly rather

2 RamoYto the bulbhokIars from the tall light

of Installation is tIM reverse 01 ,emovaL

Fairing IJIde panels 5 E...r. panat can be removed individually FIamo... the tour Krews securing tile aide

-

1** to the ~!Wing,..-.:I the ro.. ~ Heuring tile aide panat 10 lila ,,,,ring (He

.

Bodywork 8-3

,DIKonnect

the tum aignal """ng 1_ .....tratIonI. If removing the left-hand pwlM. uMC",w the knurled ring MCIIfinQ the 1IfIMdomet_ cable to !he Iron! wIleeI and draw the cable out at its gul"" below the brlka CIIlper 1_ Illustration). On 1993 and 199-01 YZF7SO models. disconnect th' fUlf twitch wlr,ng connector il I"8IT"OYing the 1II1-1\and sIdI paoli. 7 Remov. the two bolt, Heuring Ihll sldll ....tr.1Ion 3..511). pantojto the trarn. 1_ W a c.r.fUIv cnw the panel ~, noting how R angIgII with the tamg Its top edge .., ow _ fairing .tong its bottom edge. If

QONIIICIcn

".ItfV.

.ono

3.10 ' - - IIIrInO ,.......... (1IrTOWe
r..-novlng the left-hand panel, draw the IPIIdomIt_ c.bII out Its guides on till 1nIIcM. you.- K 1_1I1IIlRIion). o ......Ioon II the ' - " " 0I~. Make .... " the panel ~I" correctly W'ilh the fairing and _ faio1nQ.

--.

Lowllr lalrlo"

-I·

o'

10 RemQWI thl lour SCnlWII securing each aid' at tllliowet "Iring to each skII panel, In:! the two ao:rew. Heuo1og ..:II side at the _ fairing to the 1r..... 1_III...tretIon) . I I C8rII~ low« the panaI and .......,WI R. notIng how R tr"9fIO" with till Illring side penaIa .tong Its top IdgIoI t-

-

~.

3..1 1 Not, how It ~. with the aide

12 'Mtalllltlon II the .......... at . - a l "'-I<e ...... the 1*'ll1ocat. 0DITICIIy wItIl the

Fllriog

13 R,mo", the lelring aide pa"", (1ft

14 Ol.connect th, headlight/sidelight end Ins'rument eluale< wiring connectors II ... YIUltrltlon) 15 R _ , the two bolts securiog ,,,,, /font lilY to tlllllee..ing head. and !he two ~ aeo:umg the . . . 1liiy to the ~ bracket - ... • rag to pIOIICt the_IsM~.

I'

~
8 3..14 DI.conoect the hHdIi<;Jhtlaidelighi end ....trume
11 In.:ellallon I, the 'IV ...... 01 removal Make lUre IIw wiring connectOfl . . oorT8CtIy wid

MCO.nty~.

YZF750SP models $eal cowling 18 Remove lhe IWO screwl Meurln,. each IIciII of the _ cowling and ~ lift ~ up

3.1501 lJn$I;:nWthefronl.taybolt.

-

lit IIw front \.Wltll1Iw t-' ~ -w.g connector ~.x:eulbIe. then d-.necl it and

f'M Ih. wlrln,. from I" lie.• nd

3.I!Ib •.• andtIM . . . .taybolt.

11If1'"OWeod) •••

l'

~ve

Ihe

18111 cowtO'Ig.

..

InetalatJon.lIw.....,. of...-al

Fairift$l side panets 20 The procMlUfll II In.

,..~

u

tr,., for

VZF750R models ( _ above). Lowar fairing 21 The procedurtO if; the tame . . thel fOf VZF75CR modoIIiI (Me _ ) Fairing 22 The procedure i, the um. u Ihat lor Y.ZF7!iCF1..-t_~I.

YZF1000R models

3.18 .••

right to

IUId

--

andre....,....thel~rlng..

d~

ramovtI ~ -

II from the . teering hNd lhe headlight sod instrumenl

=. .;;:::;;::;';;;;;;;;;:::::='...,

'-;,~. . .

dust.. (:CImII wiIh IIwIIllrlng 1_ l....trMionl. Sep.nte them ~ requ'red (Me ChapI.. VI.

SIde covers 23 Remove the seat, (aee SeclKln 2) Th,

-'de co_~ .ra r_vect IIldMd.....,!y rll""

thin . . an -.DIy. 24 Ramove UIa three scr_. Meorirlg the ..,. "".... tfwI ~ poIIlIw c::oo- .~ from Ine b,~e 10 refease Ihe IWO pegs from Ih.I, rubber grommets 1_ llIul tratlonll Nota hoN lila baek oIlhe coo... .-.gagas ..... Ih the till: IIghI cover 1_ llustntionl 25 1nsUIaIlon. lila ......... of removal.

Falrift$l side panels 28 Eado panel can be removed 1ndMdoaIty. " remo .... ng the Iat\·hnd panel. unscrew lhe knurIoId mg ~ tIw ~ cable to the front wheel 1_ ~"' ltnllIonl R«oove Ine ecrews Meunn,. the S,dl panel to lhe low« fai'lng. sod the screwa IMCIKIJlQ IIIe SIde panel te the I.,nn,. and Its trim pa ..... 1_ ....." Xl RsrnoYe tIw boll MCI.IfIIIII IIw lids panel to thalTlmll t _ lIIultration 3.2!Ib). ~

... 3.24b ... and reIeaH the peg.t....,...-dI from the grommet•.••

3.24c ••. noting how the becIo. eogag&I

Bodywork 8-5

draw the paoeI_ay. noting Ilow ~ erogaoM w~h the 'linn; alon; ~s top edQe Ind the lower 'alfin; along ~s botlom edge. and dlaconr.ect lhe lum signal wIrIog connectors as they ~ acx:es$IbIe ( _ M.... tr.tlon). II remoVU'\g lhe left-hand P6JM'1, draw Ihe ~ter ~bIe out 01 lis guide on the Insode . . you rwncMI ~ ISM IIMtrMIotII. 2lS Inslillation Is lhe ~_ 01 ~

Makl ..,. the panallocIIea 00frIC~ ...,. the laring....:/ '--1aIring.

Lower 'a1MoIl 20 Removi thl thr . . !!CraWl! aacurln; IIIe Iron\ aacHon 0 1 the lower fllrtng and lil1 II aWly. not'ng how it engag.. I _ lIIu.trillon.) Remove the tht" ac ...... securing IKI'I lOde ~ thelow.'laIrin(j to IKI'I . . . paneI • ....:/ the IWO acr-. MCUrIng IKI'I llIda 01 the low. 11"'"'01 to the lrame I _ .... tntlon.)

30 Carefully lower the panelar>d rllC>Vflll. noting how II englges wllh the falrtng slda panfIIs along Hs lop edQM.

3f Installlltlon. the_oI removal.

Fairing

'*'*'

32 RerncMo lhelllmg aide Is. ~ 33 Remove the r..r vWN mom>rS (HI

""""'.,

34 Ramove the lingle acr_ on each alde sec:uring the _ 01 the IaIring trWn panel 1Illustration). 35 Disconna<;1 thl l\e&dh;hV",delight Ind instrument cluster wiring connectors ( _ illustration) . 36 Remove the two I'OJ\S MCO.ring the

_tay to

the st-.ing ""-d l _ illustration). 37 c:.etuty draw the IaIring I05$IInbIy 10 the left to di-.ga;a tile Illy boIta from tile lIewIng hMd and _ II - the "-:IIigIII a'Id 1nI""""*lI a..I. come _ the fetmg

II" Illu,tratlon), s.p.ar.ta !ham if requ,red

l_CMpI_9)·

38 Instalbltoon '- the , _ 01 removal.

MMa .... the wiring

~

_ _ conecdy

....:/ IaClnI)' connecteo:l

8

8 e 6 Bodywork

5.1 Wlndshi&ld screws (&rrOWed) YZFtOOOR rnoMI Mown

.. Rear view mirron removal and installatIOn

6.1a Unscra .... thebolt ••. •

5 Windshield removal and Installation

Removal

Removal

t On Y2F75OR and SP models. unscrew ~ nut. HCUOng each mll"for and remove tM mnor *"'9 .....tIl Its rubbw inIuIator pad ( _ Nlustratlon). 2 On YZFtOOOA mod ..., unS(:rew the two nut. l
1 Remove the .x HCuring tha wft:IshoeId 10 the fungo tamg c..n.t not. 01

5(;1"_'

the exact Ioc8Uon of the washer, nut WId protector pIecw on the inside 01 1M I.ring , _ Inu,tratlonj .

Installation 2 ""'lallation Is the ...... _

of removal. 00 not

overtIghlen the ~.

Installation 3 installation is the . - 01 removal.

S. 1b .•. and drlw the mudiuard forwlrds

6 Front mudguard removal

and installation

Removal 1 On YZF150R ....:l SP ITIQC\N, .-.movtI the four bolla .......mg the fTWJdguaro and '*- It lorw.d - the ... bolts.,. - . a d from !he inside 01 1M mudguard 1_ IMultrationsj. 2 On YZF10Q0A modeb, unscrew !he nul and remove the bolt securing the bf.ke hose clamp on each aida { _ IMu. trlltIon). Ramowa !he four bolls MCUr"Ong the Iron! MCtiDn of the mudguard and dll'lw it lorward { _ illustration) t.Ir"IIxnw the four bolts seco.ft1g !he.-- MoeIion and '*- it ~ nomg how it filS I_illustration).

Installation 3 install.Hon is !he r _ 01 _ _ •.

, S.2b .•. th .... rltmOve the lront HCtIon •.•

S.2c •.. lo llowed by tlla ...r I8(;tlon

9"

Chapter 9 Electrical system Contents AIIemator/nlgulatorll'ectifW - NfT"OYItI. Inspection end lnIIaIlallon . 32 Balter)' - e/Wgi1'lQ .

Battery _ _e!, lnetallatklrl, hspection and malnt _ _

III'\lke light SW'Itchee - chIock and _81 . ~ I~ plat. boib-l'1IMWai •.

. . 14

CIwgIng system testkIg - geo:waI information &'ld a..ging1Y'1""-~...cIoutpUItlllJt

Clutch I'Witch - check .oo..--at

9 30 .31 . ..... 23

~ ...

.

..

:1

ElIoc:trIQI 8)'SI.m - IauIIIInding •

--. Fu.I pump &'ld rNy

..................

FUII_1WItCh

_~.

...••..... _~.

F _ - check WId J1fWW1II • HarIdIebIr ~ - ctlIICk . Hano:IIeIw ..,;t~ - .......... .00 n.taIIation . ~"'-dleckWld~ . ~1Igh' .-nbty - rIn'IOVIIoI 80d Instatlatlon • HNdI~' Dulb and MIeIight bulb - reMW1II . Hom - CheCk and r.-aI .

,

5

." ,,

............... 20 .. .-ChIpI.-t

ignition (malo) .witch - check. _ .. and hstaDallDn ••••••••• 18 Ignition syst_ compoMnta . . ._ CI'tapI.- 5 Instrument _ warning light bulbot - _81 ............ ...... 11 in'trumer11 clusW end speedometer cable - removal and Installation ........................................... 15

Instruments-CheCk 8Ild..-.al .

&.n.r_- _ _ scart. ~ay -chid< and J1fWW1II

and~.

.•

•

VZFl DOOR modeII;

''''

VZF750R and SP models .

-"""""-

Wl000R rnocIM

"'-""""'"

'''''"""'" """"""...

.25

12\1.10Ah 12V,l2M YlX12·BS orGTX 12·BS YTX14-BS

12.SV 12.3V

Alternator

,--

-..".., VZF750R a'ld SP I1'IC>CWI . Wl000R modeII

12\1. 3(A. 3000 rpm 12\1, 28A. 5ODO rpm

-""'" """"".

s.r.;c. Imit (min)

. coIlWistancto YZF750A and SP modeII . VZFl000R modeIa

12Voriea

!ll!ilfIAy~(12.8Y)_T~

13.7rrm 4.1mm

S!~!Of

RoIorcol~ .

0.13 to 0.15 ohms 0 2O"C 0.19 to 0.21 oIvnI 0 2O"C 2.7 to 3.1 2O"C

oIvnI.

Regul ator/ rectifier Regulalild 'IClItaQ* output (no "-'l

28 24

22 . .. 2i

28 • •••••••••••• 27

Tum~-"""-

T..:nsignal~- _ _ . Tum signal eircuh - CheCk •

Specifications VZF750R and SP modeII;

It

21

T.. lighlassembIv-.....-I.nd~ .................. 10 _ _ _ _ lnIIailation .. 13

Degrees of difficulty

"'''' "-"

• ....... 1&

Ughling system - check . ~ 1wiIdI- chick, _ _ .-.d Ins'-llallon Oil ..... -..or and rNy - c:heck WId...--.l . Relay assembly - check ...., J1fWW1II . SidestantI swIIch - check and"--" . 5tartao" rrotor - di.-nbIy. InIpectIon Ifld .--nbIV .

U.2 to j,UV. 5000 rpm

12 • ••••••••• 11

982 Electrical system Oille"el sensor resistor 6." 10 9.6 '*"'-

VZF750R Md SP models . YU'1000A models

8.0,*",-

Starter circuit cut-off rela)'

""''''''"

VZF750R and SP mode/a .

--

Starter relay .. .2 10 ".6 otmI • 2O'"C

Realatance .•.•.•..•••.•.••••••••••••

Starter motor 12.5rnn

Standard .•.•.•......•.•.•

ServIca limit {min) Commut.ator diamat. St..-.clard .................... • .•.•..........•. ServIca limit (min) .

.""-

-.

.~ ,,~ ,,~

0.7 rnn

Fuses

VZF750R Md sP models Main ...

'"' "'"

..-

H"

Sign.II •.•

H,A 20A

1993 and 1994 models

1995-00 models

CooIngf." •. VZFlOOOAmodeis

....,

..... .....,

~

7.5A . 1 (1993/11.4). 7.5A x 2 (1995-00)

....

...... ...... ... .

"'" "A

""

7.5A x 2

-.,~

Bulbs

"""",N

35135W halQ(Itn • 2 5Wxl

SkMtlghl (UK models)

BtakWI.oI light

"'US_ """'"

2115W.2 2718W. I

I..ioIno» pIala light (VZF75OR Md SP models)

UKmodeIs .•. USmodeis ... Tim .tgNI1ghts

5W.2 3.SWxl

UK_ US_ IrlSln..om.,Hlght. . . . . . . . . . . . . . . . . . . . . . .......... . Tum ~ Indicator light ............. ... . ,,*,trallndieator light . •.•..........•...• . High beam Indicator light • . •....•••••••••••. 0iI1ewII warning Ight .................• Fu.l1ewII ~ Ilgh.t • . .•.•.•.•.•.•..•••.•.•.•.

21Wx" 2718W x 2 (front wIIt1 running tight), 2M x 2 v-I

Torque wrench settings 0iI1ewII ..-.or bolts .

Stan. motor bolts •. M ....lor~boIts .......................... .

AI models hav. II 12 YDIt aNoc1tIcaI aystMl ~ by • ttv_-phaM att.mator with IIrl

"'legnoIl"IIgIAtorlractJfler. The

~ula tor

maintains the charging

I.M." 3AW 3AW 3.4W 3."W

HW

"'m tONm ""m s pecified rang' to

SYlIIIJ(Tl output within 1M prevent oYllfcharglng, and the recl lfillf conv«\ll tile ac (a/I....ling current) output of In. alternator to de (direct cumIflt) 10 powar the ligohts and other component. and to c'*lJlllhe INItt"'Y. The all_lor rolor mounted In the top of the Cf1II'IkcaIIe lind Ia drWen otfthe ~ by . Hy-Vo c:haon. The atarW motor Is mounted 00 the top of

'*

tha crankca ..... The Itartlng systllm includes the motor, the batta')'. tile relay and the variola wns BOd swttct.. If the engInIIldI switd1 ill In the 'RUN' po$ItlOfl and the 9nltion (maio)

sw\Ic:h ill ON. the sta1. r*'f IIIows the _ _

motor to ~8 crit N the ~ II In neutral (neutral .witch (0) or. If the transmillion is in~ , with the ck4ctI ___ P'*d

Into the IlIwldIItw" and the IkIeostand lIP.

Electrical system 9-3

Note: II'M!) ... mind ItJej fIIec:trbI,..u. onee purchaMd. cannot be relllfl'*1. To .!!OId

. . - - y "'pwlse. make

'''''''POt_'

hQ

bHn

tIM

ptWT/IIely

Iden1IfIed bMn bu)'ing • ~ pwI.

.aoc.

""'*"'"

~

EIec:tric.II system fault findir.g W"",lng: To PA"'" III. risk of mort ckuils, u.. IgnllJon (mMnJ • ... /fclt m ... '''''.~ be OFF ""d In. betf..,. Mga'1In ,....../ IwmlMIlhouid be dIsconnecled bill.'. Olh« elKUIuI ~b _ t*luro.d. 00"'1 fo'V.' 10 rKon"..,' lit. ,.,."1,,.1 ..cUIWI)' 0IICtI W(ri ,. finished or If bett.
1 •

t..r.... •"" or ,,,.

"'.'ing.

1 A typIc.1 .lecIrical circuit consilII 01 10 llec;u;.;.! com~l, tIM ,wllchft, ''''ys, etc. rWted 10 thai ~ tnd the wiring tnd COI'Il benery and 11>1 IT1I""'. To aid In IocItlfIIiJ • problem in any Meclriclll Clrc:ull.

_.

10 checl< IOf Ioo...,esl which ClIOn ClIOUse imllfTTlillent fallon. 4 If lesllng lnatrurneotl goiog 10 be utitised, uselNl wiring diagrwn 10 pion whertI VOU ...1........ 11>1 -.ary~. in oroer to aox:uraMty pInpc*II the trouble spot. 5 TlMt bale for _ lault IInding a beltery In! _ _ ci'curl, I~.....sed

"conbnuity IMI«,. l.at light, and. jumper wi ••• A multlm",« ClIOPI''''- 01 Madiog von., ohm. and amps" alao very uselul as an aIIomati"" 10 ~~, and is ~ lor peortorm;ng more 1. .1. and cI>IckI

.xl"""""

. . . FIet.r

-

10 1he WImg ~ althe tnd 04 /hill troo~ IoIKlrIcal h t aludy 11>1 wiring diagnvn (_ tnd

01 Chapter) thoroughly to get. compl"'" p!clu" of what makes up Ihat Indlv~U"1 ci"cuII. Trouble 'POll, lor insIa'lctI, C*I often boo narrow..:! dowo by ooIing II other COInPCl'*'II ""'1.,;1 10 thlll CircUli "" opw.long propwly or 001. " _ a ! companenll cltclJlts 1,,11 alone""'" c:hanoM .... !he raul! lies In the ~ or ear\tI (g.ootld) conl"olCloon, ... """.... , clrcu.l. . . . often root«l through the same fuM ..-.cI ewth (orouod) cor.oec:tiooa, 3 EIaetr\CaI problems often stem from ..mp. ~ LOCh a 100M or COO'Oded ~ or " bIQwo fuM. Prior 10 any ~I 1",11 Iirdng, 1fwlI)'I ......... et-...c:k !he condition 01

Ot

tt."-. ...... _~inlhe~

to

Fault

Finding

~=:.::.~ ,... Iftl

2 Befor. tac:knng any clrt:u~.

filled. and

~

11>1 bellery from tIM bike

1_ -...r..tion). 3 On irIstalllllion. dun 1he betl«y 1""'*"'Is and ' - I .nds with • wire DrUIh or I
and ...... ahouICI 1liiio be wiggled

"r.

A

~

circurt. Intennittenl r...... C*I boo eeptdaIIy frustret!ng • I"OU .....'t always duplicll. the IaIIur. when ~'. ~ 10 _ . In aICh liluatlonI, a good prKIice • to cIMn .. COO
Sail..,. corro./on c." ~ ' 0 " ml"lmum by ~.,.,....01 ~'roMum jelly 10 !1M ,.........Ifw!he c-.... "-" bHn ~

~ ""'1" •

IN

4 _lhe_(_CfwpI«8)

~

f~/fy

-r WAI

~ ,_

.",,.,,,./y .,...

C.ulion: S. ful ..."." It.ndllng 0' WOtt"/ng .round ,It. lNIlI..,.. Thto electrolyt. /I ....,. c.tu.tk' VItI ." ~ gft {hydrogen} III gNen o f f _ !1M betf-.y /I ~

Rem Olfa/ and In stallat ion 1 RernoviI ~ rk*' • ..,..1 ( _ Chapter 8). 2 Unscrew 11'1. negative (-\I.) t",.mloll boll Inl and diSCOnOICIlNI ' - I from the bellery , . . . llktstratioro), UtI up lhe Inst&ItIing COYII' 10 acc ..... the I»&'lIv. (.....) lermlna!, tl>lo the bolt "tid d~ 11>1 INd. AIIIeaY the battery lirap Of hoId«. whertI

U<\IC._

Inspection and maintenance

-.

5 The battery filled 00 .11 model, I, 01 Ih. m,lnl""aoc,,·/ree (Haled) type, Ihe.elo.e

r.q1Mng no spec~k: II•• loIlowing cht!cQ

e CI'IIclc the ballery

malnt~. ~. fIIlou~

.till be

.~rty

I""""'"

and IIoads for tlgh'- """ corro.lon. 1/ com>sIon I. ""denl, unSCJaW the t«mir\al bolts and dilCQnnOK:t "'" INd. !rom "'" ballery, dII:ooo ...... t:Io ... ~ ~ 1-'4) lermnall'r.rt, In! dean the Ierminall end ' - I enOl with a wlr. brush or koll• •tId """"Y paper. AKoorlIcI the Iuds, cooOlCllng the ""OI'IivI (-v.) le.mlnal lasl, .rn! 'P!>Iy a Ihln coal 01 PIlroleum jelly 10 Ih. conoKlloo1 10 slow IurthIr oorrosiorI. 7 The battery caM ~Id boo I<~ 10 pr-.I cur.u 1NokaQI. -..1'kh C*I ~ the bellery ....... period 01 time (1Mj)ICiaIIy when ~ 1IIs.....-dl. WMh 1he 0lIIIide of tne e.. with. solution 0/ boIIdog IOda In! wale'. Alr>M the bettery 1horoughIy, then dryll. e Look lor cracl<s in lhe cue and ...,..... the battery II aoy a •• loutld. II acid has been spill«! on lhe IfB1T19 or bllllery box. """,tal.... H with a baking soda and ... 81.. toIutlon. dry ~ thoro\lghIy, then lood! up 111)' ~ peiol II II lhe molorcy<:l. sill unused lor Ioog periods 01 time. ~ the IM
c""'"

bItIery lenTIinaIs.

~

(-....j 1.......aI1k'sI:.

9

9- 4 Electrical system

f:'...:-;:f. ~--------: :

"I--I--t--t--t--,

............

3.10 Me.-. ~ voltage 10 _

~

condition 01

ReI. 10 SectIOn • and ctl&rge the t..tt..-y

oroc::.

~ month 10 . . _ _ 10 ,.... conditIOn 01 !he banery can be ~ by -"'!I1hI1dIage ~. the beltery I........,...:l ~ IhI fiIr.n against the chari !_ lIJustr1ltlon) . Comect !he~ ~(... v.) Pf"Jbe1o lhebettery poeItfv. (.......) terminal, and \he neoa\lYe (......) prQbII 10 lhe bIIttery naglll.1 (......j lermlnll VI'tItn fUll)' ~ there IIhouId be 12.8 YCIbI (or morl) prltHl1t. II the YO~1 1IQfI fills below 12.3 YOIII the banwy mUSI be .-.moved.

~Ihe~"'-!-w)t"""'first,

wid rIIChIrged .. dMQt)ed in SectIon 4.

,

T ~

battery

1Iottwy -

"""'...

w"'"

_1_ . .

tr1ItIon).

ComIc1Ihe c:twv-

\0 the blttery. maIWIg ...... _ tIw ~ (.......) Ieed on 1hoI.::IwgIor iI COfI!lIded 10 Ihe pos/tIIIe ("'118) ta'nWIII on lhe banery. and the neostiVII 1-....) IeIId II COfI!lIded to the ~ t-vel1lrTnNl. The beltery ahould be charllOd lor lhe spKlfled lima, or ...,1iI1hI IICfOU Ihe IIImIinaIs ,. .ctlel 12.8V (allow the battery to SIabiIiM for 30 mlnulll 1ft•• charging before laking • voltlgl , . .ding). Exceeding Ihl' Cln "'uM the battery to oYMh"al. buckling the plltH wid randeMg ~ usej ... s. F_ .,.,....... wi. ,.... ..cc;au 10 .n .xpensi..... cu .. en' cont,olled charger. so WI oormal domestic c1wger Is UMd check INI Ifter I possible initial paM, Ihe charge 'all falls 10 I Mle ,.... (I" 1II"llrIUOII). II IIw t..ttery becomM r.ot

volt"""

lithe cnarv-r doesn't have ...

.....

during charging I lop. Further chlrilng wtII Nole: III ~, the batt..,. un be cMrfIIKJ ., • higher ...11 of .round 3.0 .",ps for I period of I hovt. ~ ...... this l.ool'IIC(M,,, ... idId er>d,he .bw .-np d\I/p1Ils Ily fit" Ihe lifer" ...... /t1ocI 01 c/IaIpIrIQ Ihe barr.
Clulioll: B_ IIXI,...."eIy ca,..ful when hndlillfl 01" won lllll l l"OI.IlId thl bltt.,,-. Th _ _Ieclra/yt. fl ~.,,- cI .. 511c ,"d '" lIIp/(nllll fII' (hydt"oflln) I, 1I/vIII off Ihi batt.".,. chlrg/nfl. , Remov. the baltery (see Section 3). 111101 '*-IV done. ""'" 10 Section 3, Sl~ 10, wid check the open circuit IIOIt.agI 0I1h11 benery. Raf..- 10 \he chari and ,ead off thI cr...gIng IirnII"IqtncI _ding to !he YOItage ruding 2

.... met .. built In, c:onnect _ In ......... 8hown. DO NOT c:onnect the ..........wr t.et- !he t..tt..,. tenninIb or It WIll !No

:

.-

c:hecII and rerwwal

~

..."

1 TheIleClrleal system '- protecled by ~ of dill .....11 '111"11'. All .xcept the maln fu . . ... houNd In tN fuseQox, which ~ located under tile rIder'. seat (_ Illull.. tJonl). On YZF750R and SP model,. the mIIln fUM II moo.nted on !he fronl 01 !he bet\ery bo>: btiIow 1M lull tank ( _ lllustmionj. On VZFIOOOR modIII. the mII,n fu . . Is inlag,al with the starter.-.llly. wI"kh II loc.IIed bet*'d Ihe 1Ifthind *Ie CO¥er 1_ iIIuatnrtIonI.

Electrical system 9-5

2 To acc., th" fuSflbGx Iu",,", 'IIITIOVI lhe ,od..-'s s .., 1_ Chaple, 81 lrod unehp lhe fusebox lid 1_ Illul tratlon) To _ _ lhe mII,n IUM on VZF750A and SP moxrer. , _ the luel lank ( _ Chapt..- .) 1_ III",tr"tlon S. l e) On YZFlOOOR mc>
the...-v t - .... trallon Sold! 3 TlIII tu_ can be r..-noved 1"11 ehecl<ed ~. If you can'l PIlI the Iingert'~, u.. 1 suilable

" - OUI with 'fO'X Pl''' of ph ..... A blown tun It NSIIy Ideotl. Ind on YY'1000R models I II*" "'-' " 11;I"l0<..-.:l In \hll1IIa't..- relay "I splrlluM 01 used. always replace It wtth a _ one III) thai I &pari of -eh "\log .. carrled on the bike at an timell. Wotmml1' Nevw put In I tu.. of I , higher ratinll 01" brl~ thl tarmlnall wlfh .ny o fh.,. su,,-"'u'a, Itow ...... temporery It may t>a. Serio<.f. ~maga mI l' be doni 10 the d-cuh. D' a fh may .stMt. 4 " . " - blows. be ..... to ctIICk !he wiring -V etr.tuIIy for evt(IerICI of a.r>on:e .. euit. Look lor bare wj," and ehaled, melted or Dumed Insulation. If th" luse I, re"lIWed belOfI the cause Is ~ted. the new I ..... will blow immediately S Occaslclnllly a luse WI" blow or CIIUM an 0pII!"I-dI"CurI for fIG otMous _ . c:orro.Ion of the IUM ends .,.., fuMbox 11fITW\II, may occur and CIIUM poor fuM contact. II tN, happens, _ lhe CDn'OIOIIfl w,'11 a Wlfl lin*! or """'Y ~, then tpray the ...... ..w;I Ind t _ _ _ with eIecIneaI contac1 cIMner

s.--

A

ci_,'

6 Ughting system'hook 1 The bItt~ Il"O"idM power for operation 01 the hHdhgllt. tad light. brake 'oght. lurn

signals and 1nt~t cluster lights. II r'IOfII of lhe hghts opeo"ale. a lways chKk ballery voltage belor" proc:OIeding_ Low ba\\ery voltage MiCal" ellher • lautly ballery or • deIec1iYe chargong syIIeITI. Reo!.- 10 s.ctlon 3 for bllrtery ~ and SIcbonI; 30 and 31 for cIlargong ')'Slem t .."". Abo. check the con
Brake light

Headlight

Instrument and warning lights

2 If the heldlog/II ,.... to work. check the

.....S.

first t-M $tc:tlon 7}. U- \hII "-1_ SectiOn 5), Ind the "''''ng """"'8Clor. then ~

cl>eck for tlallery voltagfl al the yellow (HI beam) andIor greeo (LO beam) wire leon,1III on lha wpply "d" 01 tha head light wlnng connector. If volt.g" I, PI ...... n\, check Ihl ea'th {ground) circuit 10< an open or poor ~.

3 If no YOItage .. IrdcIled, c:hIck till ......mg batw-. the i">Hd'oght the di ........... ,w;tet!. light>ng S'N"et! (EuropHll modIIIs) and the ignition SWItch, then check the ....... ,chIt

-.

Taillight

4 U tha ,." light

connector ......... on \hII

taillight lode of \hII wling connector .,.., 11'11 COfTISPO!"Id,ng 1"""'I\I"S Itt lhe bulbl>older. If voltage and c:onlln\lily ara pr""""', check \hi earl h {groundl CI,cull 10' an open or poor ~

...

~ . If YOItage .. prweoI. cheCk tha e.th (ground) c,rcuit for an open or poor

"""""'"'

7 If fIG voIlage IIII"IIoealed, check the brake light awttchM 1_ Section I.). lhen lhe wiring toatw.eo lhe tall fighllnd Ihe swit~.

fI

5 " no lIOItage 110 Indoealed. cheCk the WIrIng betwe«I lite tall Ioghl. the lighting ,w,'ch (Europewl modeII) and the Ignition IWltch. then chick \hi swItchM ~

Sotebon 17 for i"IItn.mInI and W1WTling

~~

Tum signal lights • If """ light fails 10 won.. chick the bulb and Ih" bulb termina l, li"" Ih." lh" wiring COMIC\On. " r>one of the tum l1li"""' Work, IQI cheCk IheIMgllal " 10 If \hII ~ III good, _ SIcIIOn 11 for Ihe \u'n IIgnII circ\lII ctIICk.

Headlight bulb and sidelight bulb renewal

'''It

10 WOl1<. chack tile bulb(sl and the bulb terminals and wiring connector Ii.. t I _ Section 9), Ihen tile t-digtrt ....... then c:hIck for battery YOItage at the blue/red "''''' lermillll on th" supply sidoo 01 the tIiIlghI wiring connector, wiU'I\hI ig.... ,oon awllen and light"", SWTlch O N II YDhage It ~I. chack for conbnuily baI-.!he~

fI If the braka light fall, to work. check II>a bulb(a) and the bvlb lermlnall and wiring coronectOf firsl jail s.ctlon 91. IhIn the sIgnIoI hna. t~ checl< for De\\ery 'iOItage 1\ the y.aIow ....... ,...,..... on !he tuppIy aida 01 !he 1111 flghl WIfIng conneclor. w,th II>a Ignition ,,,,,'ch ON and lhe braka _ or pedal

it

~

-<:

N01., The headl'gllt /xllb I, ol lha quartzIII/ogen /)'pl. Do /lOt /tJc1CJI !he bIJoIb ~ .,

.,.,aci
~

/Wd>«J, /I should be

~ ca-MIy"""" cold WItIIa fIQ.aahd'"

maIhyfa/ed sp;m _

A , -

dri«I botIctN 1fIt0'lQ'.

Wa rnlnll' Anow '". bulb time to

cool "'tor. ,..,.,o~lnll It If th" IHIadIi¢II " . . /till baoM .,..,.

-

Headlight 1 On YZF1000R modeIl. lor best access 10 Ih" hHdnght bulbs. _ v i llIe lalring skIe

..

panel on ~ ~ tide \IW Chapter 8). but notathat ~ 0I1X*ibII. IIbIit 1IddIy. willi

•

9-6 Electrical system

7.211 Disconnect tke wiring connector .•. 2 Discoonect the relevant wiring connectOf from the back of the head light assembly and remove the rubber dusl cover. nOllng how ~ fits (see UiustratJoos). 3 Rei"""" the bulb retaining dip. noling now II ~ts. then remove lhe bulb (see Ulustnolloos). 4 Fil I he new bulb. bearing In mind I he On!ormatoon in the Note above. Ma~e sure the tabs on the bulb f~ correclly In the slots ~ the

bulb houSing. and

se~unt

the rtllainlng clip 5 Install the dust cover,

it in

pos~ion

ma~lng

with

sure II Is

7.2b ... and remove the dtlst cover

correctly seated and witll the 'TOP' mark at the top. and connecl the wiring conneclor (see illustrations 7.2b and al. " Check the operalion of \tie headlight.

= •

HIN

Always usa a paper towel or dry cloth wher! handling new bul/n to pilIVent Injury If the bulb should br....11 lind to ing'fUlSf/

Ixllb /ir",

7.33 Release the clip •••

7.3b ••• and remOve the bulb

7.7b ..• and detach the lens

7.7c Pull the bulb out of the bulbhOlder

Sidelight 7 On YZF750R and SP modals. remove the

screws securing the Ioos and retTI()\Ie lhe 1008 (see illustmtions). Carefully 1)1.141 the bulb from Ihe bulbhokler (see illustrations). Instalilhe ntf10H bulb In the I"dder.!hen Install the tern; and tighlen the screws - do not overtighten th"'" as \tie 1008 Of Ihreads could be damaged. " On YZFlOOOR models. Ihe bulbholder is acce$5ed via Ihe underside of the fairing. Tum it anti-<;Io<;kwise to release il and draw It out of Ihe head light (see Illustration).

7.7a Remove the screWl! (arrowed).

7.sa Release the bulbholder from the base of the headlight

Electrical system 9- 7

--

c:...tuIIy pulthe bulb out 01 IIW _ 1_ ....1r.tIon) .....'-1 the ' - bulb. the buIbhoIdet ..-.c:I tum it cIockwIM to loci< II

u.. ..._

f Chedc !hi operation of 1t.1icSeIIgI'rt.

8 Headlight assembly removal and installation

Re mova l 1 _

FI.movto the lairing

(see Chapt ... 8). then 1M inl;lN:MnI duster fnIm the I.mg

~kdonl5}.

2 On YZF1000R models. releele to. turn sIgrlIII wiI1ng from tn. c"ps 00 It. tHIng ( _ II ..... t ..lIoo) OIscoonact the hNdllght wiring conn«:tOlI and ........!;to 10. sidelight bulb_ from tn. headlight (_ Utul1 .. t lon) ~ Ihe lour screws ..,;uring Ihe firing IllY - ' _ I h e IllY -'ong WIllI the...mg ( _ ....trMIon). 3 R~ Ihe fooJ. saews HCunng the I>eNIght ..-nbIy ....:1 if! it out 01 the Ismg (_ lIIu.~ .

9 Brakeltail light! licence plate bulb -

renewal

~

t On YZF750R Ind YZF 1000R models. remove Ihe ~ _ I ( _ CI\IIpt.. 8) On VZF1SOSP modeII. f~ the _ c:owmg (-. CtwpI..- 8). On V2F15OR _ SP

u.. • a --.100 IcIr>ce ~. light, whie 00 VZF1DOOR models the taillight bulbi

4 m.Ulllstion If; the revtIf'M oI.....aYII. MsQ .... .. Ihe wiring If; correctfy COIlI"IIICIId and -=tQCI. CI,..;II the operatlon of the "-lIght and IldeNght. Check Ihe IINcIllght .. m (IN CMp\.. I~

L2b 0 1 - " Ihe hHdIlghl

~

eonnaetore (arrowed) and ramo ... the

-~

..

fTIOdeIB

4 Ftt the buIbhokIIr Into Iha taillight and tum it cIockwIM to HC\.Q it, "'laII Iha S6III

1Ibo"""'*>a1oo tIWIc«Ic:
01

Brake/ t aillight bulbs In'taflatlon

and cIeIn them ~ ' - Y - l.Q up !hoi pinII Ol lhe new bulb with the eIo\s In the socket. Ihan push t he bulb In and lu.n II clockwlH un t~ it locks Into pllea. NOla: The piN on rtNI bu/tI .,. 01'fwl1O It CM"I onlY .be ...._ ..... w.y. /I .. a good idM to ... a ~ foweI 01 dry cloth when /IaIId1Jng It!a tIIW buIO to .c:w-w -"!UY If It. bu/tl1houId btM/r fIWi to

2 Tu.n the bulb/IQlder anti-clockwl .. Ind withdrew it I.om lhe tall Ilghl (_ lIIustr l tion) Push lhe bulb Into lhe hold... and _ it .ml-elockwisa 10 .......,... it (see

"*'

oowtIog (_ Chapter 8).

Licence plate bulb

-

e To ._w tfle licaoca plata light on V2F15OA and SP modeII, ,"I """"'" !hoi tall light -ooty (sM SectiorIIO)_ u...cr.w IhI I'IUbI MCtJring It. Iicanca plata light and O'aw it ofIlhI t.ck, IhI --..., pial..

8.2<:: Ramova the K ' - - (arrowed) Mel lilt the • ..,. out 01 the III" ng

'.311 Headlight mounting K'-- (arrowed)

3 Chack the IOCkal lannon. . 101 eorroaoor>

"*' _

_ YZF750R . nd SP modtoIl

aIOellght bulbholder

-

t.2b ••. tt..... . - - the bulb !rom"'"

•

9 - 8 Electrical system

-

noting how II ~111 , _ IllultrIUom). Draw 001 Ihl bulbholdera, Ih"n pull Ihl '1llvanl bulb

out 01 tl1-t holder la_ iliultri llonl). Fit the ' - bulb, than Install the IIghI and the laillighl

10 Taillight auembly removal and installation

~,. ~

--..;:

Remo"al 1 On VZF750R models. remova the pillion seat. and on YZF750SP models. fW!I(MI the seat cowling 1_ Chapter 8). Ramo.... the t>u~ from the tM light by tuming !ham anti ·cIockwiH 1_ Wkratratlon). Unscrew the bolts securing thelall light and draw ~ out the back 1_ lIIultrationl) . l! On YZFlOOOR modahl, ramo.... Iha ,.". hand aide eo_ , _ Chapler 8). Eillw fW!I(MI the buI:lhoIders from the tall IIghI by Iurnlng them ..,U-docI<wIM 1_ IUustrftlon •. bl or dosconnecl the I" lighl ..........tIIy wiing <:OnnICIor 1_ IIIUlltrallon). RI!fJ>O'Ie the _ securing the lop COYer to

taillight ..

to-lib Remove the ~ bolts (8) ••.

~

and the

g.5d . . . and fh the ne .... bulb lhe right·t.and aide

00Wf. and the two bolla ~ the taillight bracket. than I'fIOl1O'Ia the 11" light, bracket and lop CO\'er . . an

uaembly 1_ nIUltrltlOnl). RerrlO\1 the bob MCIri'Ig the talllIghl to the bracket and separaieihem 1_ Mlu.tratlon).

Electrical system 9- 9 InstallatIon 3 installation II the . - 01 re
....

1 MoIIt tum aIgnaI problems ..... 1M resU! 01 • burned out bulb or corroded lOCket. This is especially true when tl\& tum signals /unction PffiI*IIIIn 0<"4 elr..ction, but r. to IIIIsh in 1M other ellrectlOO. Check the bulbs and tIIa IIOCket, ( _ s.et~ t2) and tile wiring ~_ . .-...0, chtck the eIgnaI fuM ( _ Section 5) Mel the swiIdI ( _ s.ction 20). 2 The t.n-.y PfOYId- _ l o r IIJ*'IllOn 01 the tum """'" ~ . . il1IWf do no! opwaIa, IIbo chick the bMtery ~ Low ban-.y ¥OIIage incIicIIt.. IIither • IBUIty bBttrf or a ~ cr...pr.g I"fStern. Refer to SectIorl 3 lor bIItIafy ct...::b -..:I SoctionI30 and 31 lor c;hwgIng 1)'81'" t..1I. 3 II the bulb •• IIOCkets. COfll'lectOfS. tuse. • wltcll and batt-.y _ good. check the tum signal relay, whk:I"I is mount.., """'" the, ..... _ i_ Iliu llr~on". Remove 1M fuel tank lor access (_ CMpt. 41. " cn.ck lor voI!age 111 thol brown wino In the relay ~ OOI"f>ector with the ignition ON. W no ltOItage is Pf..u. UIIng the appropriate wiring diagram at tile and of this Chapter ch«:k the wiring beI_ 1M rlltay -..:I the igrIrbon (maon) IWItc:II. If ¥OItaQe was ~

chtck lor voI1age 111 the brownIwhitfi wire with the ignition ON . .-.cI witI"llha switch turned to

eltherl.EFT or RIGHT. WnollOilage II~ . _the.-.l8)l. W¥CIIage was~. check the wiring bottw.an the rMay, tum BIgMl • ....ttch and tum -'II ..... 1Igh1S for contl",,,ty Tum the IgnlUon OFF when the check "

........

.

.... ""'-

the ON bulb wIItlthe eIots In the lOCk", ~ pull! the bulb In Mellin ~ cioc:kwIM 1.Wl1iIl!

3 Filthe ...... onto the hoIdeo". ~ .... the tab 1ocI1.. COfr1ClIy ISM ~ . Do not overtlgh,.., the .crew as the ...... or ItvMcII

couIdbe~.

13 Tum signal assemblies-

12 Tum 8IgMI bulbs -

removal and InstailatlOO

~

1 RemoVfIthe KrfIW securing the tum llignal

I"". and ..moVI tile Iins. noting how It m. (_IIIustr.tIon) 2 Pua/t the bulb

~to

the holder and twist It • ~ I .... to ........... ~ 1_ 1IIustnotlon) ChId< the IOd!It ,..,... lot com:JI01 Mel elMn them 1/ neceasary. Una up the pins 01

Front Aemoyai 1 Remove the IllIring stele panel ( _ ChaIpI..- 81. On YlFl000A modeIa. rwnove the Inner panellrooJ the MSe paoeI- ~ is HClAcI by to.. ICNWI t- ...Iration). 2 RImo:>w the _ _ ..:uring the tum signII to the K\aOcIe 01 the fairing and .......... 1M II'IOI6ItIng pIMio ~ ~I. RImo:>w the tum signII !rom the hiring. notng how ~ fils. T.... I*e not \o..-.g the wn.g. yco.o pull!

-.

Installation

3 Insteltlllon is the reverse of removst. Make IlI"l th, wiring Is correctly routed Ind securely conr.ected. Check the operation of 1M tum aignaIs.

Rear Removal • On YZF1000R mocIeis.

-fittlng_ . . .

12.3 Makl ...... 1M tab IocaIt .. conwctIy

1'fII'IIO¥' lhe pillion

13.2 R _ the moo.wrtIng plat, 8C>TM ~Md~theaigMI

Sit

9- 10 Electrical system

1l.5t> Rear tum sigoal wiring connectors YZF1000R modele $Bat, on YZF750fl mod ... ls ..... mov ... the sid ... CO\IOOI, and 00 YZF750SP models remo"" the seat COwlIng (see Chapter 8).

5 Trace the wiring back from the tum slgnal and disconnect It at the connectors ($Be lnultmt\ons). IS Uru;cmw the nul securing tile tum siQnal to the inside of the mud!luard and r... move the mounting plat ... ( _ illustration) . Remove the lurn signa l from tha mudguard. taking ca ..... not to snag tt1e wiring as you pull it through Ins tallatio n 7 Installilltioo Is the reverse 01 removal. Mak ... sure the wiring Is correctly routed and secu ..... ly connected Check the operation 01 the tum sign.als,

14.2 Front brake switc h wiring connectors (AI all(! mounting &Crew (8]

14.301 RONIr brake light switch (arrowe<:!) YZF1000R model skown

14 Brake light switches check and renewal

Circuit check

~ ~

'"

1 BalOfa checking the switchas, check the braka light circuIt (see Section 6, Step 6). 2 The front bl"aka light switch Is mounted on the undarslde 01 tha brake mastar cyllnd .....

13.6 Thto tum !Signet Is secured b~ a nut (arrowed) on the inside of the mudguard

banery voltage. If there 's no voHag<'! Pl"IIS8I1t, check the wiring between the switch and the Ign ~ ion switch (......, the Woring DIagrams at the end of this Chapter).

Switch renewal Front brake light switch 5 The sw~ch Is mounted on the underside of tha brak e master cylinder. Disconnect th ... wiring conn ... ctors from the switch (...

illustration 14.2). 6 R... move the single screw and

[);s.connect the wiring connectors from the switch (see IItuslratlon, . USing a continully ttlSter, connect tile probes to tile lannlnals of the $WItch. With the brake tever at rest, \hers should be no continuity. Wrth tile bl"aka laver applied, there should be cont inuity. 1\ the switch does not beha"" as described, replace ~ with a new one, 3 The rear braka light switch is mounted on the Ins.kko of the frame on tile right-hand sida, above the brake pedal (see Illu stration) . Remova tha fual tank t o sccaSB the wiring connector (see Chapt... r 4) . T,ace the wiring Irom the switch all(! disconnect It at t he connector (see illustrations). Using a continUIty taster, connect the probe!! to the terminals on the switch side of th ... wiring connector, W,th tile brake pedal at rest. thera should be no contlnufty. Wrth the brake padaI applied, there should be continuity. II the switch does not behave as d8SClibed. replace It with a new one 4 If tt1e switd1es are good, ct\eck for voltage at tha brown wi,... terminal on the conneclOf with tt1e ignition sw~ch ON - tt-... sho<Jld be

pedal (sae illustration 14.3a). Remove the fuel tan k to 8CCtlS8 the wiring connector ( _ Chapter 4). Traca the wiring from th9 SWItch and d isconnect It at tile connector (see Illustration 14.3b or c). Free the wiring from any clips or ti es and fead It through to the switch. g Detach the lower end 01 tha switch spring from tha bra ke pedal, then unsc ..... w and remove the switch. 10 Installati on Is the 'eversa 01 removal Make Sure th... brake light Is activated just balore tha 'ONIr brake pedal takes effact. II adjustment Os .-sary. hold the SWItch and tum the adjusting ring 00 the 5WItd1 body untO the brake light Is activated when requ~ed,

14.3b Rear brake switch wiring connector - YZF750R and SP models

14.3c Rear brake switch wiring connector - YZF1000R models

washa~

securing the switch to the bottom 01 the master cylinder and removtt the switch. 1 Installation Is the reverse of ..... moval. Thto swHch isn'tadjustabl .... Rear brake light IIwitch

6 The switch Is mounted on the inside of the frame on the r\ght-hand side, above the tlraka

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9-1 2 Electrical system

15.:)1 ...

I fairing \JIm 1** 10 the fairing, ...cI the two _ _ toIClIIing the bottom of the wIndehIaId I_~. lift the iIstnment c:k.IsIer aIorIg wrth tha trim panel out 01 the 'airing

1_

lllull. l tlon) . Unscr_ the knurled ring IMICUring lhe epiMdometer cable 10 lhe bIcI! of the speedometer and deI;och the ClIb4e 1_ Illul trlllonl. Un!IC.ew the two nuta Heuring tha Instrument clust"'" to tha trim panel aocl draw the clUSler out of thl front I_ W....lr1Itionaj InataJlalion 4 Inltlillohon II the '~M of .~I On VZFIOOOR mcxIoIIs, make IUrI the \rim I*""Il locltea cOlTeclly In the 'airing 1_ llIuIlr1Itlon) . Make SoUre that the ~"'" c pb ll and wiring conneclo..... eorreclly routad lind IIC......J.

Speedometer cable Removal 5 RemoYe 1111 fllflng lsee Chapter 8), then separatl tlla Instrument cluster !rom II 1_ abovII - thatl II no need 10 .epartlte the !nr;lrumenl clU$!.,. from .;tiler the fairing lIay (YZF75OA and Sp) or trim panel (yZF1000R).

6 Unscrew Iha knurled ring Heuring the $ptItIdomete' Cllble to the back of tlla speecIorMt,r and detach the Cllble 1_ illuslr1ltloot 15.21 or 1l5.3e). Installation 7 Connect till cable upper end 10 the speedometer aocl tighten the .eta ining ring ~ 1_ llluatratlon 1s.2! or 15.3a). 6 Installhe Ia1r1ng (Me Chapter 8). e Check that the cable doesn't r•• trlct s t-v.g movtIITIOfIl or interf",e with any OIh.,.

_0.

2 Ramove

the apaadomatar cable

1_

$action tS), rod d>ack II..t ~ II no! seized

ore r

(It

broken. Replace ~ with • ~ ~ RemoYoo the Iron! wtW (.- ChtIpt.,. 7). 8IId d-=k that the ~ ~ rotat.. lreeIy. CleM and re-grease n. RepIac. ~ wfth • MW ore ~ nacessary. Slmllllrly d-=k lhe drtvero ge.ar on the back oI lh11 instrument duater. Renewal 3 Remove the InsllUm.,1 clust... 1_ $action 15). 4 Remove the..-.lng _ _ from the back 01 the duster and loft 011 the front cover ...-nbIy 1_ llustratlon} IJnacraw the odometer Irlp

knob , _ IIIU I I.a tlon) , Remove the two ICr_S securing the lpaedometer oearbo~ aocl lin off the box 1_ Inul lrationj. Remove the two screws MCUrIng the ~ter 10 the ea aine. Care lul~ withdraw the speed· ometer from the Ironl.

16 )nstrumentscheck and renewal

Speedometer

15.4 Ma kl . .1 the trim 1** '""""" correctty wtth the fairing (an'owIdI

Check 1 SpaclaIlnstlUments are required to property check thl opet"allon of this met.... II II I, believed 10 be r.utty, takl the motorcyde to a Yamaha dealer !Of - - . e n ! . BeII
1$.Aa Ramowo ~ ~ \8f'rOWed) and lift ott tha front .,........

Electrical system

5 1nataIIatlon;. Ihe _ _ 01 _ _ _ .

Tachometer C .... k 8 SptICiIII iNtrumenta ... ~ 10 IlfOPIWIV chOKk Ihe oper.,lon 01 Ih~ meIer. II It is believed 10 be laulty. lake the "",tortyl;" to . Y.nW dMIer lor usessrneI1l

-'. Renewal

7 R_

I_ ...........dont. ltUaJ. f*l1OYtIlhe

__

Heuring Ihe Ihree 'achomet. wi... and delactllhe ........ noting wtlich ~tI wheno ( _ lIIust... tlon). Remove Ihe two ac.ews Heu.lng the t.chome,e. to ,he cuing. Carefully wlthd.aw ,he , _ , . from lhol

Ihe right-hind iIIustretion 18.131

Chook R _ 10_ Seeo.pter3.

a~II!he

_ _ oI _ _ _ .MaQ

c1u,'.

1_ IIlustrrioo'ls HIAa).

...............,-

It,,"

13 Removi !IW ac •..- sacUrlng the lemperature gauge wires and de,ach tlla wires. IlOtlng which fits where

,

1.

'ermlnal

17 lnatniment and warning light bulbs -

11 Remove the inltrumellt cJ,..t.. 1_ Section 15). 12 RIomow \he cuing ~ In:m the t.:II of thol and tilt off the Ironl cov. ~

15 I"'tallatlon II the _ _ 01 ","",val. MaQ . . . the wtmg II COfT8C1ty corv>ected. As 'fOIl look ., the b8ck 01 thol c/ustl!ll', _ g .............:l wire II lot ,he top 'eonln.,. the bIacI< lor the lett-hand ,....".,.,. and tt. brown

lot

Coolant temperature gauge

'he Insttvme..u clusl.. ( _

8 Remove!he..-.g.,,--. II'om Ihe t.:II 01 !he '*-I • ...cI ill 011 Ihe/rool co-.- ~

""".

.,.. Ihe v.irIng II conectIy COO'nICted. Iw you k>oIr. • Ihe t.:II 01 !he dutter. the brown WW'I It lor the 1eft-hMd tern'i'\aI, !he bIId< lor Ihe midd .. terminal. and the g.ey 101" the righthand terminal (_ lII,..tretIon lUll.

I'"

carefully wtthdnrw Ihe tempera, .... gM>ge

g e1 3

renewal

(. . .

~ ~~

t:

1 RamoYoo the IMing ( _ Ch8pt.- 8). Some 01 ,he bulbs a.. acc.aible wilh the lnstNmer11 In tItu In Ih8 fllirlng, while Olhers can onty be acceued IIII!II' lOloI)ar.lting ,he Instrument clua'er.nd .I,her Ihe lalrlng stay (yZF750R ,nd SP) 01" trim par>el (YZFllXXlR) from K 1_ Section t 5). 2 carefully pull the bulbllolder out 01 the n.trum8n1 CUIng. pull the bulb out 01

cIu5'.

"*'

"

9-1 4 Electrical system ctIecII the oontlnuity ollhe connector lermlnal pal.. ( _ lhe Wiring Dlqams al lhe end 01 this Chapl..,. ConllOUiTy IIIloI-'d exisl b e ' the lentlII'\aIa connecter:! by • said line on the
Ramol/EI'

17.2a PUU out the butbholder ••

;"';',,"~''''';'''''~M~ :,~:~"~,"~.~ :;,,.~":.~).;.~,~"~e ~

3lnatall

laIrIrog

\lie(_ inslrul'r*lt and/or .. ~ SectIon clueter 15 and/or Chapter 8).

18 Ipnition (main) ,witch -

check, removal and Installation

~

i:::

...

Warning: To pre ...nl Ilta rIU: o( I .ltort ~h'c:ul'.. remo ... Ilta _ , • and dil~onnKI Ilta battary n~a'l~a (-v.) I. .d ba/ore ma~ln" any ignition (main) Iwltch chKlcs.

A

Check , Remove the fairing (see Chapter 81_ Trace \he IgN1Ion (maon) SWitch wiring t.:I\ from \he bas. 01 the SWII~h and disconnect It at Ihe conneclO", (s_ lIIul lratlon). Mak. IIIe cheeQ on \lie swilch IIIde 01 \lie eonneetor. 2 u.InQ an ohmmeter or a continuity 1"1",

4 Position lhe molorcy<;le on en aUlUl1efy stand to thai Its weIo;tM ;. off the fronl .-td RemoYe the fairing (.- Chlpter 8). Trace the ign,llon (ma,n) switch wiring back from the basa of tile swilch and disconnect It at Iha CO!'II'IKtcn (see Iflullrlltlon 18.1). Ortow Ihi wiring through '0 thoI IWIIch, freeing It from any d;p. or tiM .-td nobng ib n:IUIng. 5 I../nserew \lie boll MeuMg the fronl brake mUler cylinder, and on YZf7SOR and SP modeIa the clutch master cyHoder, to the lOp yoke and displace ItIthem (_ lIIu"trllllon) • KIIIIp the masler ~I) upright to ~

IUd 1MkIige. til RemoYe \tie blanking CIPI from the heads 01 Ih. handlebar polilloolrlg bolll USlrIg • smali ll al -~aded acrewdriv .... then un.crew \lie bolls (... lllustr.tlonl) 7 s.cken Iha Ior1I ~ bolts in the top yoke and the hendlebat clamp bolts I_ IHUItraUon). Unscrew the Ilewlng slem nul end re!T1ovt1 It along wllh its washer, where 1~led (..e illustration) . Gently...,. the lOP yoke upwards off the tori< tubas and remove ~ (see IIlultratlon). 8 Two PIear-head bolt, mounl the ignitIOn

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9-16 Electrical system

20,. Loc.t. 1M pro (A) in 1M hole (8)

VZFHIOOR models, W remoYing the left'hand switch, remove the choke cable~, noting how ~ lite.

Instal/atlon • tnatln.tion ;. the rev .... 01 removll. On YZftOOOR models, refer to Che.pter • lor Inllallfltlon 01 tIM chok. cable, If IWqUIr.,;l. Mak, I.... the IocatlOg pin In the IwHcI'I housing local.. in the hole In the handlebar t... IIIUII •• llon) . Mak. lur. the wiring connectOl'l .... correctly routed .nd securely conneeted.

21 Neutral switch ~ check, removal and installation ~

Check

'"

1995-011 YZFl5C mo<;Ml. .nd .u YZFIOOO modal, ""VB" s&COIld and third gMt posJ/ioI1 unsor combined In rhe neutral ~ ... Itc". The$l senson .re linked to the IgnIrion COI'Icro/ uniT (see WitInv diaQnImS) .00 ~ the Ipn/rIorI tinW>g cherKterlsfiCI to be Note:

r:IwIfIId to ..., ~ t a.or. c:hec:king the eIec17lc8I ch:uII, ct*"< tIM bulb 1_ Section \7) .nd f ..... lsee Section 51. 2 The IwHch Is Iocaled In the 1eft-1Wl(I aide 01 the lranlmlssion casing below lhe IroI1t

sprocket, Mak. sure the transmission II In neutral. To acC\IIS the J'l8Utrll .witch/oIl level II8rI$Or wimg conoector, remove the /uti lank (... Chepler .). Trace the wiring from the

swHch and dlsconl'llCl ~ Illhe conoector ( _ IIlultration) , 3 With Ihe connoc:tor disconnOC:led and the Ignition ,witct.:l ON, the neutral light 8houId bot out. 1/ not, the wn ~ the comector and Instrument clUlter mull be . .rtMod (grounded) at _ polm. • Check Iof contnuity ~ the light bkIe ........ t~ on the ,wild! aide 01 the wiring conn«:\or .nd the crankcase. With the transmiuion In neutral. lher. lhould be contl .....ity. Wrth the transmi$sion In gcNII", therao Mould be no continuity. If the test. prova otherwise, then the . wltch is raulty. 5 II the conUnul1y t . .t, prove the .... Itch Is good. <;heck lor volla~ {ignition ON) II the brown ternW'llol on the wiring loom aide at the ir'IstrumerIt clulter ~ oonnector - _ the 1etI.f>erId f.n.g lode panel to IICCMI the connector. 1/ therl" no voItagl present. cI'Iec::k the ...... batW6erl the conn«:\or.nd sign.lluse ( _ th. WIring Dil starter clrcuil I I delcrlbed In th. r...... nt sectionII 01 thiI~. If all componenQ;_ good, check the wiring belweer. the warIouI componenb 1_ the WiMg Diagrams 1\ the end 01 thiI Chapter1.

tha connoc:tor. then r....... ~ from any II.. (... Illustration 21.21. 7 Makl sure tha tr.nsmlilion II In n&utl1ll. n.. switch Is Ioceted In the lell-hand aide 01 Ih. transmisslon casing bMow tt.. front

""""".

8 R«nove the front aprockeICOYer (Me Chapler 6, Section 16,IoIoWlng the .......... Slape). I Oisconnect the wlf. from the 011 lev" .....,.. st the single buIIeI connector. to R.""",. the.cr.ws lIICurlng the swltch and detach It from the casing illustration). 0IscM1 the O-rlng, Il5 I new one must be used. Note the routing 01 lhe wiring . . )IOU draw ~ through.

I."

Installation It Fit a new O-ring onto the IWllcl'l, then 1",1.11 the Iwitet! and tighten Its 1ICrew8 IICl.IfeIy 1_ lIustration 2t .10).

12 Feed the wiring up 10 th. conneclor, making sUre II II corroc:tty rouled. and COI'\IlIlCI ~ (.... iIIullraflon 21,2). Secure the wtring In any tIM. Connect the oil level sensor wiring buDet connector. Check the operltlon 01 the J'l8U1raI11ght. 13 Inslall the Iront Iprockat co ....... (SH Chapler 6, Section t6, IoIowIng the ~

" n Inst.1I

the lull tank and the left-hand

lairIng aide panel (see CIlapt.... 4 and 8).

Removal 8 Rornovd disc:<.IIVIICt ~ at

22 Sidestand switch check and renewal

CINK_ t The lideatand swHet! II mounted on the P;t'lSland. _itch II part 01 tile sallly circuit which ~ .. or 1I0fl1 the engine nnW>g If IhII ~ II In QIIr whilst the sldesland .. down, .nd ~s the .ngine /rom starting il lhe Irllil,mlssion Is In gear un~ the sld.stand Is up, and unless the clutch Is pulled In, Belortl checking the .-:trIcaI c:Irc:Ut. c:hecIt the Me jaee Section 512 TO ICC88S the wiring comector, remove the lull lank lsee Cl'uopter .). Trace the wiring Irom the Iwltch and dllconnect It at the OOIII'IeICIor(s) ( _ IItuItratlonI).

n..

Electrical system 9-17 3 CI-'< the ~ 0/ the switch ..,.Jng ... Dhn'wnIIIer or ~ _1ghI. Conned the meter ~ to the t...,inaIs on the awltch lOde 0/ the ~or With ttw Iidosta-Id up thtr. WoouId be conbnurty (Ie«> fftistaoce) b e t _ the t..."o.ls. end WIth lhoe ,,1_ down there IhouId be no conllflurty Qn1init.

--

a ~ the _do ".... noIl*fotm • expected. It Is deIect ..... and mult be re..wed. 5 11 th. swlto;:h II 900d. Ch«:k the starter ar<; ..m o;:uI·ol! .....y and 01'- oomponents III the I tart... o;:Ircu~ .. cIes<:r\bed III the oectlona 01 tm Chapt .... " __ components .... 1/OOd. chec:l< the wfrlng DetweM th. various CCIf'lponefIts {_ the Wiring ~ at the .00 0/ IhiIc Cha¢eI1.

,"""'ant

Renewal e The aodIet.nd IWlto;:h Is mounted on the sldestand Removoe the fuel tank ( _

ChIpt. of) 10 _ _ _ ttw WIring~. Trace tile wonng from !he sw,tch and diKOllneo;:t It It the conntK:1orjs, I_ .... tntlon or b). Wor1< bedt -'eng the • wltCh W,ri"ll. f""ng It lrom Iny ""'.V"'" retaining cliPi and toe.. IIOtl"ll its COOlecl

zu.

....,.

w.

1 Removi the ..... MCuring the switch and remcwe the switch. noting how ~ flts 1_ liluatnotlon)

......

22.1 "The lldestend .wlto;:h is sec:w..:I by two ........... (.,-owed) g<>O(I. d'leck the wIriIIg bet........ the various componert\I IBM ttw Wiring ~ ., \he IIIld 0I1hII ChapIer).

Renewel of The Clul(;h awllch ,. mounted Oft tt... unc\tf'IIde 01 ttw dutch ........ br-=ket. 5 OiIoconneo;:t th. wiring connector I_ _ t1ntIon he _ _.. .... 23.21 fWIIOVtI the _ _ WId

"*'

15 lnstaIetoon Is the,...,.. 01rernowI.

24 Relay auembly check and renewal

8 At the MW switch. milking iIoUre tile ~ kx:ltt" correctly. Ind tlghlen the screwl

, "!aIle IRA the wm.g 15 COtTectty !'OUted up 10 Itt. conr>ectorj.j UId reta,ned by IU the ~.IIIldl*. 10 RecoIIneo;:t the """;"11 o;:ofVIeclorjl) Ind

chec:k the OI*a\lon of the ldIsIand !IWItch. 1 t Install the IueI tank t- Chapt ... of).

Starter circuit cut·off relay

c ..... 1 The.c_ c*cutt o;:uI-otf ~ _1*\ ~ the NI...,. Cin:ul1 whtcl1 pr.......11 or 'I~ the eng"'" IUfVWItj If the t".....tI'u.1KIf1 is in geer Whilst the IId8StInCI _ down. IIIld ~ the "'"'Ill"" /rom alart'ng If the transnusslon ~ in (IUf ........ \he tlt:lesland .. up and the dutch

23 Clutch switch -

check and renewal Check 1 The o;:luto;:h sw,tch II mounted Oft the undersld. 01 \he o;:lutch lev ... brac:k.t. ll>e SWito::h II part of !he Nlely ciro;:Utl which prevenll or II~ the """""'II If the t r _ Is In geer """"'" ttw sidestand Is dcMn, IIIld ~tI the erogtnIIlrom startng W the lrantmlnlon Is In gear unless the

eng'''''

~ .. up ItICI the c:kItch Iewr Is pulled in. The switch lIn't . . . .tabII. 2 To check the switch. ~ the WIring connector I_ Iliul treUonl Conoect the ~ 01 ... Dhn'wnIII ... or I o:ontirUty test light to the two swito;:h termlnill. With the o;:luto;:h Iewr pulled In. contInurty IhoUd be indicated. Wrth !he cO.lto;:h Iewr 0111. 00 conthJIty (InfWt. ~ [0/'lI')0'' boo indicated 3 II the SwitCh I, good. chec:k the s tart ... dn;uIt o;:uI·ol! rNy IIIld other o;:omponenll In the ltarter cW'co..t1 .. deKrIbed in the ......., ~ 0/ IhII Chapt .... W. . oompor_ua _

,...... it puI\ed In. 2 The lIart.. clrl;u/t cut-oll ,ell y I nd diod.. If. conliined within the rellY DstembI\I mounted on the Ironl of the battery box below Ih. tan k reef mounting 011 VZF150R and SP models. UId on lop of lhe 1ueI~. which it """ behind \he fuel pump. 011 YZ~I000R models ( _ lIIustrlltlon., Remove lhe I...., I""k lor ........ (!oM Chapter.).

"s

23.2 Clutch awltch wiring c:onnec;tor ~) and mounting (B)

--

so;:,_

3 0iI00Mect lhe retay wIting c.onnacIor and ~ \he relay. Ref..- k> the wIting dIegrem for your model 1_ end 01 chapter) IIIld ttw

of To o;:!>Kk ttw operation 01 the reIIy. ~' _ _ k>Ihe<:Jtwn."'00...-.gll.

or. o;:onbnulty '"'er. betwe.t the blue end bI""""hlte wire t.""lnals of the ,elay. No contlnu,,,. should be shown. Now utIng jumper wIr. . "",""",t • rully o;:harged 12V battery to the 'elay'a blll<;k/yeUow and rtd/'bIeo;:k ....... lermInaIs (positive (.. ...) Iud to ,edlblack and mtgal iva (-vej lead to b la.:klyellow), Tha meIer should allow c:ontInuity with battery voltage applied. 5 On YZF150R a nd $P mod.ls • ligu re II provided for the cul·off .ellY resistaoc:e. Conneo;:t, melerll8l 10 the <:Jtwn. .. l 00...-.gll

~ the ~ WId redJbIeck....". I~ 0/ the NIay. TlwIiguN gI-. in ttw Spedflcelkli=.,the tIegirYIirIg of thoa chJtpter .-.oukI be obtIIned. S The d,1Idae o;:ontllned w,\hom the relay ..-nbly o;:an be ch«:ked by perform,ng I 00fII1nuIty _ . Ref.- to the ~,. ......-.og dl"" .. m ., tt... end 01 this cf1apter and COI'II'*:t the meter (... t 10 the ohms lundlon) or o::ontlnulty t"t ... across the wire 1.""lnait !or the rllt>rIft holing t...ted The diode should , how con',nu lty In One dl'&<::tlon and no oontIn"'ty when the meter Of test .. prObeoI ... 1/ th' dKKla show, th. tama o;:ondillon In bolh directions 1\ should be

-,_Md,

~ the CIII-out relay UId diodes ... proved gooci. yet the starting system IIUII slil exists olller components in the stert,,,,,

1

checII ..

9- 18 Electrical system

an::uoI ~ tIw I*IIr1II switch, SIde ~ swItdI. dutch MItch, It8rter IWIIch and Star!IW relay!

as described In tile relevant sections 01 thil ChaptIW II .. oompo....-II.. a"9 good, check tIw

wiring be1w-' the various components

lsee

Wlt1ng ~ III tIw end 01 \his Chapter).

Renewal 8 The .elIY ........ bIy it mounted on the front 01 the bllll!<) bo~ below th_ tank .ear mo"mt",; 01'1 YZF750R Ind SP models, and 01'1 top 01 tile IuaI IUt .... which Is just behind the fuel pump, 01'1 YZF1000A mod.... (IH .ustration ~.2a 01 bI. Aamove !he IuaI tank

lot acc-. t - Chapt ... "I.

e

--.

.. II the hom

00-., 1IOUnd, replace 1\ wtth I

Renewsl

:I The hom II mountoo on the bottom yoke, Remove It.. fairing for besl access 10 It (see Cllapler 8). e Unplug lilt wiring oonneclors from the hom ISH IMu$lratlon 2!1.3a 01 b) . Unscn!w the botl secur'Ing tilt hom and I'fIO'I"IOVe It from the bike ISH II.-Itsllon or 2!1.3e or b). 1 l
Installation .. the ~ 01 ,.....,."..

Fuel pump m l.y 10 The IuaI punp relay is housed within the .elIY aoI-MI!IbIy. ~« to Chapt« ... Section

t."

'Slot o.talfJ. Oil level sensor resistor 11 The 011 level ""sor .. sl~tor is hou.1Id

WIthin the ....y ss-nbIy, Aeferto Sect"'" U 01 ttus chapt«1ot test det8h

26 Oil level sensor and relay check, removal and installation

check and renewal

Check 1 It the horn, doesn't wort., first check the fuM lset s.ttion 5) Ind the ballery (see

Section 3).

2 The hom I.. mounted on the bonom yoke. Remove the ,.. ring !or best access to It (see CIlapter8j 3 Unplug the wiring COIlnectors from the hom (SH IIlulltlllonl). U.. lng two jumper WIres, IIflIJIy banI!<) vottage directly to the terminals on the hoom. lithe hom sounds, ctleck thl sw,tch 1_ Seclion 19) and the Wlring ~ the swttch Ifld !he hom (sea Wri
S; ~

'"

Check

1 W,lh th' ignition s witch ON and the kill

twitch In the 'RUN' pOsition, the oil level wamlng light thoukl nol C
<Me

25 Hom -

ahouId come on, Indieltmg thaI 11M 011 tev.I his ~ as tt is being pumped n:uld the ~ the light does not come on, .. top the qinl and checI< the bulb 1_ Ssctlon 17}, If the bulb is good, check lor continuity In the WIre bottWMn the sensor bullet connector and the loom side of tl1
qlne.

-.

3 To check the sensor,

~

It from the

....."., ( _ Step& 5 lind 6 beIow). Connect one probe of ." ~ 01' COIlbr'luily 11$1« 10

the IW\SOI' wt •• and the other pr<>t>I to Itt baM. With the sensor In its normal instlilld poaillon (wiring 1\ the bottom), there should be contlnuity_ Tum the sensor upside down Ther. should ba no continuity. " .. tiler condit"'" dON not occ .... replace the ....... with I __ one. .. To chick the relay, remove the fvel tank (lie Chlpt.. 4), th.., disconnect the relay wI~ng COIlr.ector and .ek!a5s h from It.. holder (. . . Ill ustrltlons). Set a mulhmeter to the Qhms x 1 tc/Ile lind connect the ~ (..... ) probe 10 lhe redlbtue wi ... 1"",,,...1, snd the negative {-vel probato the black terminal Ther, lhould be no continu,ty. Letlvlng the ",,1« OOMICted, and using s fully--ct.ged 12 volt bIIltery Ind two Inlullted jum"",

.' ~· ·iI:·~'H' 'H~"H' '·~F· ' -I""F"I 1"'-'1< >~""" q. ~ j' "','" £H·!..~ ~~l ~~I i wh~hi •• :' .l1'. !<·~!'

"1-1' ··1i I i.01r ;;:,'; lil!I!.I; .!_.. •;li~1 ••• "!t _ 10'" H.t1 .j •• ~l • . 1 .~:l.~ 1",( ~I

1

jl

.--. !I~!' •••• ~11'l~fl _! 11,li~ ~.. ' . ' . fll" '. hI"[I ."•••' :~.~.~ " .. ~ "1" '."O"j' h'

• -

Ii - ' . a~

p

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i'

_0

~l.~;;;fl~g.:::();~~Q 5'

."'~Hlh'" ~--~~ ; ~~ ~ ~

iin ••. ~ g "

"1 J• . " - ,-" .... " ~-

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~f~ ~j

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g g~ .Hl~ :~~g, ~~

l" O' I "! ~ g· l~

!~ii

i;~ Ii _3Q.~

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~i~ '~I ~

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.~ 1= §~ -::r

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13

:i

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li i~ '.ih

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ag. _ _ il." _ aD. ~~ i : " , .l" i 9'< •• Ii"

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im

li.~,[i

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:'.[ 1

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= s.:Ui.ai$~ , -~

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i5":i;=Q: p .. !~f

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n~~~ -q Ie&: i~5

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81

tg~ll5

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§~.hf~i ~ :xI~" ~ ~ ~ =!1 ~

H,~··n If!~i ." .. z-.,..

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1 .. ~g ~t~ i~ I~~~~··§-§.

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m

[ ~

1 fff'"

~

W

9- 20 Electrical system

4 Set I muIIII'nIMer to tt.. CJIIrN ~ 1 ...... .-.d connIICIlt .:nlM tt.. rWy'1 ..,., motor .-.d bIottwy Iud termkWt (nwi<1Id 'M' Ind '8' rMPICItv.ty) ( _ lIuw.tIon 27.2c) . l.I$ing. fut\i~ t 2 volt bllttery and two inlUlatlld lumper wires. coonect the ~tl". (..ve) termlnat of the b;tn-V to the •..:\IWnlla wi,. lermlnal 00 the .eIay. and the .... tlvto (-vto) ........ to tt.. _ r'fZFl000R) ot bIue/'wtoitto

(YZF75OR.-.d sp)

-e"""'"

on tt.....-y.

III trill point a. ~ IhouId be '-'d to <*::k

and tt.. multmIt _ _ 0 om- (contonuit)1. H

U. ill the ~ 1too:t..eay ill provad good. H!he relay doeI I"lOl click wIIan battery vol. Is applild and Indicates no oonllnulty ~nfinlt_ IWIStanoe) ~ ib terminals, It II fIu.Ity and nIUIl be r.pIacId with • MW one. 5 II tha .elly Is good, "hKk fot ball...,. ¥OItIgI .t IhI recVwh~a ........ I ........... on !he loom . , . of the f1IIay wiring connactor ""'IhI .tlrter button Is preued. It .-oItage II ~I, ~ the other <;OmpOIlII"Iti 1'1 the ltarter <::ireult as dlsc:tlbe
($tie W..-ing

~.t

fT>OdeII the Itott'hand side co..... ( _ Chapt_ 8). The ~ relay II located behind thl ban.y on VZF75OA...:I SP rnodeIa, .-.d on lhe I.ft-hand tlda of IIIe ban...,. DOK on VZFl000R modIIs ( _ Illustralloo 27.21 or b). 0Isc0nn«I tn. l">;.Itlary neoa1ivl (_) lead bel",. ~ the al at. relay. 1 ~ the relay """log ~OI" ( _ illustration) IJrwc:tew the two bolts MCIrtIg till "..,... motot and banery "'lid. to 1111

relay

-

and

oetllCh

the

IMcb

1_

illustration 27..2c) AImove the ..eay ""'" ~ rubber.tee.... from mounting IUQ 00 lhe

"a

8 Insta llation Is the ...... _ of .erT\Q\lal. The slarter motor lead connects to the t ... mlnal

marl
28 Stltrtef motor -

8 Retr'Iow; the ridtr's _1,...:1

st_

maiOI', ""'king ...... It .. -'lid in Its Il'00\II, and IITII8r h with grease. 8 Manoeuvre thl mOIO' Into pnsltlon and ,Ilda it Into IhI crankcase laM flJullration 28.3bl En.ure that IhI starter moIor teeth I!-.h correctty with Ihose 01 the .tarter idIWr«Iuc:11OO gaar Inslllf IhI mountfng bolts wid bghf ... !hem to tt.. I~ . .!ling spacil'led II the beginnlog of !hi Chapter I_1IMtnItIon 2I5.3aI. 7 Connect the lead 10 the 11..,,_ motOl" and MCUnlit with IhI nul (.... Mlus tration 28.2) Maka sure the rubber cover Is corrllClly _ted over thllermloal. 8 Conoect tt.. battery I'II(JItivi ......, Hoad ...:I ....1811 tt.. _ t ~ Chapt_ 8)

29

Starter motordisassembly, lI"Ispet::tion and reassembly

~ ~

Disassembly

the and

Removal

on VZfl000R

5 FI\ a MW O-ring onto the end of l1"li

removal and Installation

of 1"'1 Chapler)

Renewal

Installation

1 R _ the rlc*'...., and the Iaft-hand Iiuring IIOe ....... 1_ CI>Ipt« 8). WId tt.. lull I.-!k (_ Chapt_ 4'. ~ tt.. batt...,. naoa"VI (_) lead The starter molot II; mountlld on lhe crankcas.. hI!'IInd IhI cyWIder bIoei<. 2 Pili back IhI rubber lermlnal COIIII" Ind un",....... the nut ..curing Ih_ IelId to thl starter motor II " IIluat'allon). Detach thl

1 Ren"IOva the starter molor 1_ Section 28) 1_ illustration). 2 NOlI the sllgnmll"ll mlrks between lhe main housing WId the front er>d ..... CO'o'a'I, '"

..,

3 Unsc:r.w IhI IWO bolts secorIog IhIstarter molot (I" IIhlsl,.tlon). Draw tile ."rtll" motot out of lhe crenkcaM and f'IfTIO'IiI it

\he macNne (1Mon fllustnttionl 4tn:.m Rerncwa the Q-riI'Ig the _ 01II"1II _ _

"-

motor and dllCWd It IS a ....... one m .... t hi

28.3b ... _......,... \he _ _ motet"

Electrical system 9-21

211.2 Nole the e ligon.....,1 m ...... _ _ the houOJolng 8I1d end co~ le"Owed)

.........,

malte your own if lhey ar""'1 c,", 1_

3 I..InIo:ww 1N two long_ bob,_ nobng!rom1N haw en. _

~1o<:at. ,

etan.- motor t - amr.tIonI . • Wtap tapllrol.W>d the leech an en. _ of the _ .... motar"''' - trill; wII _~

prot«;t the oil .... from ~ .. the !font co_ Ie removed , RemoVfl the fronl co_ 'rom the moto<. RemoVfl the cover O-ring from tile ma.n nouaing and disca'd ~ as I . 0<11 m"'II ~ "'!Jed. RIKTIOVfI tM washer and III ..... !rom the Iron! end of the ...m.lIlQ Iheft 0< the I~de 01 the !I"O"I cove<, notJng IIIW ecmcI ~tted IoeatlOOlL

15 R~ the rNt co....,. and b<\I-"~ete uaembty lrom the motor 1_ iII",strallonj. R _ tile c"".. O-ring from t... main houIing end
_ .fI. ........ .......

the IrmIlure ahal1 0< from Inside the ..... !hi bnJehpIIIe -..bIy ... " - '

I Will'ldrl. 11'>1 arm.lur. from the mIln

211,1 Starter molor COlT\POf'*lta !

()."'v

2 LMQ boll

3 Front_ H/;Jt4Ing CHtv .w.h IIoowhg

6 8eant1Q 7 0/1 SNI

8 w_ 9 SIWnI

7 NOllng the correct folted IocaHon 01 each component, unscrew the nul and _ 1 1 ~ with Its washer, II'IIIlnIuIeting waahe<1 and the O-ring, Wltl'ldr.w the term'n.' bolt .nd brushplat. lasembly lrom the .... _ 1_ Wlustratlon) I Utt the br1.IW1 'Pf"ngs _ $Ik\e the I:>ruI'-

term'n.'

0UI1rom II'>Iit holders.

!O~

r7--~.s---

r----------~

•

9- 22 Electrical system

29.11 M - . . the brush lengtto

Inspection II The PfI'U; of \he ~ motor !hat aMI mOIIl

likely to ,.qUIr' anention at_ the brush... Measure the length of the brushes and compate the ..... tts 10 the Hlngth listed in this Chapt.·a Specifications (.e. lIIustratlon). ~ any 01 the brush.. are worn beyond the service lim~. rwopIece the brush as&MnbIy with

• new on.. II the brush.. are not worn exceeaovety. nor cracked. chipped. or 0Iher
Ihe commutator .nd compa.e II to lhe epeciIlcelton. ( _ illustration). H It has worn below u-.. wlWlf hm ll ••. . - lhe starter motor. Measu ... th' depth of the Insulating Mica

-.

below 11"4

......,ace of the commJIator OOrl. H

the Mic. is 1ft, than lhe deplh specilled. scr.pe 1\ ,w'Y unlll lhe specified depth Ia 11 USIng en ohmmet. or • conllnuily t.t t~ht, chek tor continuity ~ Ihe

29.11& ContInuity should I.lat be"""" the commutat ... ben

commutator berI t - WIu5tnrtlon). Conmu
........

~

14 1nepecI\he end C1CIYWI for Iigr-. 01 cnckI

or _ housing _

Inspect the megnets In the m.ln the housing Itself for cnckI.

15 Inspect thol Insuleting washers and front

eov« ail MIll for sogns ol damage and replace Ihem wtlh new ~ H necessary.

Reassembly HI Slide Ihe brushes baek InlO posillon In !heir holders BOd place the brush spring ...;. ontolhe~

17 EnIure IhIIIIhllInrW" n..t>t.. insuIetor II In place on the I~ bolt, then iii the Q.flng _ Ihe t"""""", Insert Ihe bolt tIYough Ihe ... _ end iii \he brushpIat • ...nbIy In

1hII . . . _ . milling SUN b tab is IXIfNo(:tIy

ioCIIted In the slot In Ihe co-. .... 1_ IllUltretlon 211.1) . F~ Itle insulating washers _the t..."nal. Ihen fit the standard wl$her and the nul. 18 Slide the shims onto the end of the ...... Iu.. shell. then lubricat, Ihe an.1I end with a drop of oil 1_ Illustrllllon). I...., Ihe .. malu ... Inlo the rlla. cover. Ioc.tlng the bn.IaIln on the commutator bars . . you do. t.kIng ....... not 10 ~ n-n. Cheek Ihat ueh brush II MCut6Iy prUHd sg.alnat the commutlll'" by Its spring _ is ..... 10 ..-.ow

'N'

eesit11n ita holder

''I F~ a new CHIng onto Ihe msin houaong F~ the housing _ the IIfTTlIIIl.n end onto the .-- cover••'igning the mart<. .... de on

.......

20 AppIy • . . . - 01 grease 10 the lip' 01 the fronl _ 001 seal end fit a new O-r'ong onto lhe fronl of Ihe main housing. F~ lhe w..... onto the cov.. Slide the shims onto the fronl of Ihe .. matu.e shall. Install Ihe cov ..... aligfwIg the marks made on removal. Rernoo.. the ptOtICItve tape from the shaft ~. 21 ChKk thol mari<.s made on .emovil '" CotrIICIty Ihgned. then instal! Ihe long bolts end tighten them secu.eIy 1_ W....tretIons 29.2 _ 3). 22 1nataI\he start« mot... t- Slctoon 281.

Electrical system 9-23

..

opera!.o'lg ,.".....,.... F>.emtwe the _ _

30 Charging system testing -

~

generallnlonnation and

7 To ct.dc the NgUIII.:!..an.g. 0IIIput, _

""""~

the InghaIO O;kn ~.~ . . to the 0 to 20 VCIIta OC {voItmeIer1.c.... the terrniMll cA lIMo boIllery (posiM (+ ....jlMd tobaltery~(+ .... )~, .-..gatIviI(..o,oe) IeIId 10 bettery ~ (-ve) II....WIIII). Slowly Inc:r"-. !he engna 'PMd briefly 10 5000 rpm and noI8 the ..-ling Otltained. The regulated voItaga aI!OUId bot u apecified .t _ beginning 01 the CMpt... If the voIIage .. outsde 1'- ~ml'-. chock the aIt..... 'orl reguII10rlNcttfilr _ StctIon 32).

"*"

I II !tie peo1ormaoce 01 tile clINging ')'Ilem is llMPKi. !tie system .... wl>*.tI(MJid be checked fhl. fDllDwed bV t"lJng 01 tlla Indlvidu.' components. NO!t; s.1ote ~

lhecl>ecb. ",.. . . . I!'NI t..n..y.

!Ufy cIwg«J WId .".1111

srs""" CClfV*:IXInI

... dtIn-.dT1ght 2 ct.:Iang!hl CO.IIJlUI of !hi c;:tw'gIng . . . . 8IId Ilia ptI'form.n':t 01 lilt v.. ~ compooenll wltlun tilt cl\tr~ng 1)'I11m ~ !tie ... 01 a muIImtt. tMtI'1 vott.ge, currtnl lind ~ chtckIng ltoelIiIiM). 3 When making Ille clltck•. follow Ilia procedu." ca.elul ly 10 prevent incon'lIC'! connectlOn8 or IIlort CIff:uJlI. U I,,~rable dao:nagII; 10eloctrictl -VSlOlm ~ ""'Y .-./I H thor! <;IrcuIs occ:u" 4 1/ • """Ill..... '- nol Iht lob 01 ~ &Ie d\trging tySMm should be left

31.3 C"-cklng ilia ~'lJIng IYltern ... k.g, rate - COfInlCt Ilia ...."" as Iohown

2 R _ , the

KrIWW ...,urIng !hi brush hoIcIIw. nomg the 1Ied.........,;l by 1M bonom

'1IIila!M.

_, _

~age and output test

i-... ~

1 II lhe charging system 01 the machl ..... is lhoughl 10 bot Iwlly............ !tie _ I (_ Chapt« I) _ !*form Iht /oIowIng ~

Leakage test

A,..,.,.

C.ullon, COI'InK' .n .mtrNll.... In • ...,........... In 1M~He/ wllh Ih. ballIH)'. o~ It will ba dMn~ 00 no! 'um Ih_ Ignll/OII ON or op_r.', Ih • • I.".r mo'or whirl ,IN .mm.'", II conMCllKi - • • udd_n ,u'VI /n cu .... nl will blow Ih. trNIl.... "'...

2 Tum

lne

.............

ignition

.wttch

~

,.... I'WJkIer (.... lIIu."'IIIlO<1) Inspect lhe

Check

31 Charging system -

.......... the hokIer. noIIng""'"

m. (_~. Rtmov. the =-eo- from

to.Y_detleror~~

IA ill

W. rnlnfl' To p~ ...nl Ih. nslc 0' clr~ull •• "mov. Ih. . . . , Ind dl,co""KI Ih' b.lllry ""flltl... f·~'} /fled bafo" rn,U"fl I"Y c:hac/I. MfIIe -"_tor. 1 R.......... the Ieft-rw.:l fMing side P«MI i_ Chapl. I). Rtmov. _ line botts ...",.mg Ih6 alternator «III _1IItd nmDYII the eoYef

.hort

i_ ....IRtIon)

hokIer tor .,.,. sigrw 01 ".",... Mea. . . the bru.h lengths ISM Illu.,,,llon) . Un/or!unlIleIy. y ........... proo.o;de no ~tions lor !tie .l¥M:Iatd and rnInIrnvrn bnJih lengths. but

il the bn.Ishet are otwloolly worn Ihor!. rapIaoIlhe brush hokIer --.b/y wi\tI a new one 1/ the brusI\M ... not worn "cessiveIy. nor """"'-I. chippIId. or -..... ~ Ihey ""'Y be ra-used.

o.n the ~ mg. ('the

contact..,....". the _.""'moist... __

rIng$ on the 5h2tt wIid1

~l

"""-E

OfF .nd ntgttIve

~ Iht"" from U. ~

3 Sal Ihe rnul\1mate< 10 the Arn~ IUl'lCtIon 'nd connact ~ neoal"'" ~) probilo lne bellery nagallvti +-ve) lenninal. and poUt... (.....) prot,. to the discor'necItd negat .... '""") IetId (SM Mlullrlllon). AlwD)'I sel Ihe mal. 10 • h.glllUTlpll range Inillally and than btIng ~ down 10 lilt mA (mIMI Amps) ranga; ~ lhera It I high currant !low In !he citcutt ~ .... y blow lhe met.... fUI •. • No cun-.nl !low IIhooJId bot Indlcal.,;!. II currant -.ge It indocaIlId ~ l1"l'i* !han 0 I mA). there II • IIhort CItCU~ In lhe ~. UIing the wiring dagrwnt II the _ 01 lhit CIIapt". 'yslemalJcaliy d*onnllC'! ~ tIIactfIca! ccmponan!a. chtckIng IN meter eadl ,.". ,.-,tillhe ~ It kMnIi1Ied. ~ II no leakage il Indicated . dilCOMKllhtI met. and connoct the ~ '""") 1eIId 10 the boIltery, tlghl«lirlg It MC'-""'Y

Output fest • Start _

IngIne _

......... It up to norm.!

32.1 Unlerew th, bol'- (...-owed) end ,,_e the co.oer

32.21 Undo the screw.

"..-owed) .nd

'"""""'" tIM bNII\IIoIder •.•

9

9- 24 Electrical system

3 To chck the rotor coli 'nlstanc:.. lirst

allSftl'T1bly II laulty and should be repla<::ad

r.-nove the ~ ( _ above), \hen HI a mult lmelerto 11>8 ohms ~ , (ohmmeter) lleala

WIIh a '-0f"Ie II CIlecIc lor continuity batweerllhe allp rings

and mMSUre the resistance

be~

tl>8 sUp

IingII (tr. mgs on the Ithf,fI wNch contac1 the bru",,") and com~a Iha ,..,d'ng 10 tl>e Speclflcauons. II ~ II. hlghar than specifled. repIIICe the rotor WIth

a ~ 0I"III.

4 To clleclc the stalor coli , . .Istance. HI a mu~im8 Spec~ical~ II the beginning 01 the Chapt"",. and tl>e8 ,ermlnals and 9,ound (fNlI'Ih). If not. Ihe al1emator slator cod

WICIII>8 IUIDIII .... no....tng. n-a should be no continuity (infinite ,"Istance). II t..... I, conPnUi1y. ~ the roIOr WIth I ~ one. II Yamaha do not provide any till SpecificallOnl for the ~or WId ~_ If none 01 the ch«J\1 made here or In other Sections of the Chapter n!IV
_'iable.

Removal 7 Remove the lat!·hIInd!awlng skje paoli (wM Chapler 8) end the fuel tank (see Chapter .).

8 T,ace the wiling from the alternator/regulator/rectifier and disconnact ~ a! the cornector 1_ Illus trations). FNd 11>8 wImg bad< to the alternalor ass.nbIy a Unacre...- tile th,.. bolls HCUflng the

altematot allSftl'T1b/y to the crankcase and

Wlthchw It 1_ lIIustratlotll)

Installation 10 In.,.II,11on I. Ihe ,ev..... of removal Tighten tile bo"I to the lotql.le ,...l1Ing epeafiad at the begIo:ri1g 01 the Chap\a'

6

12

-

17

il

•

!I -

l

. to

1'-

111-=

f

... II If

1 ~

c-

, 'n

f

'V
or;::..;;;J ,!

~i I

~l .I ~

'·I1.=.l

..-=

Ii

1,1

L=J I

Ii

II

J~HI

ill ~ I! o:ur,

[ full

L-m-;{ -<:V, {t

+----H-i~

I II

""'""..:

~ lUI DleJ ~. J~

.I r

.I!=--= 1! " I~ II " I~ "1- <-.;f

I

.'I'~;"-+< L .... . ~>-~ .j-.. ,,~

c.::....J

Ilf

1

I!\r

= 11

n

9-26 Wirirlg diagrams

raDlm

~

:n

1

I

i

1

I•

II

f-

Wiring diagr,ams 9·27

1

-~-

I t

.

I ~')il -

i- -

i--

;I I~ ~--4-+--+I

.. r -= il'

~I

i

I_

lit

=

I~

II m )

=::; HI

I

II

rx::=l l

III

~t iii 2r:

,I ll

0-,

g

'" ~

II

~

II: 0

rc"'

N

.) I

>-

It

!

! 0 1)

!

9

9 0 28 Wiring diagrams '"'

, h.

1

-

~I 11 :::

II'~ ~

!ln~9~ 1 ~!::!:-1=F===;-tH-t1r---1r~o~-n '"

I

I

I i

Wiring diagrams 9.29

9

9.30 Wiring diagrams

I

I

I~~ ~J

i

i

IU~ ~

-

i-

-

~! ~~~~~~~t---tt-t---rt-.~

I,·e

,0;

,~

•

!-- ! ""-

L...::!ltJ ) ;1

II

I--

~ 'I

=

1.1

••

xii

: :: '-"-' ,II III -@JIl l!

r="lll ' ~

I'

t jl

r= ~I

iii

2-

I

II § a:

~

""""

I\.'.>!

,

0-1

.....

II

') I I I

?

It

;

,

~!: i

I

.~

~

uN

>

Reference Dimensions and Weights ••• • •..••. ,REF o1 Tools and Wor1<shop Tips ...•........•.•••. ,REF o 2

Conversloo Factors

.REF-20

Motorcycle Chemicals and Lubricants ........ REF-21 MOT Tes! Checks.. . .. ... REFo22

Storage ..... Faull Finding Fault finding Equipmeot •.

Technical Terms Blplained Index

REF·'

.... REF-27 ..... REF o 30

•. ,REF o 42 ...... REF-46 •. ,REF-SO

Dimensions and weights

YZF750R

""""""""-

E~rn:>deb

All us models

VZF1000R

2160 nwn .20romm

•.

--

""~ • •....•....... 1165nwn

ev..e height. SUI hejghl

""""'-~ Weight (with fuel and oiCj 1993 and 199<1 models l~modeIs • .. 'FOJr add ,

c.wo.n.. ".,...

78!imm

'.2{)mm ,.,~

. 218 kg" •.

/Iv

..221 kg'

YZF150SP OveraIlength .

-""-

o.....n wid!

.

0..•• 11 hetghl .

""""'---

.2 1110mm

"'~ "'~

1145mm ,.,,~

,.,~

w.ighI (with tu.I and oil)

1993 ItId 199<1 models 1995-00 models

.215 kg .218 kg

""""""""' _"""""""....."""'-

. • 2065 rrrn

"'~

1175.....,.,

Seat height

1997-"" modeIa

"""""-~ W.,;ght (with full and oil) 'For c.r;~ modIIis add , I!g

.81Smm ........ 790mm

.1430nwn .140mm

. .224 "".

REF- '

Tools and Workshop Tips

Buying tools

For more Informat fon about tools, .IOfer \0

the Haynes Motorcycle Workshop Practice Tec/lBook (Bk. No. 3470).

toolk~

is a fundamentaJ requorement for sevIc/ng and repairing a moton;yclo. Although thM8 will be an lnotial expense In building up """ugh loafs for sef'Vlclng. this will soon be A

offset by the savings made by doing the job yourseII. As e>
"' ........

As a rule. it is better to buy more expenSive. good quality tools. Cheape. tools are likely to wear out fast... and need to be .............cJ more

often. nullifying the original sa...tng.

Manufacturer's service tools

The following lists 01 tools do not represent

the manufacturer's

selVJC8

tools, but S81\'e as

a guide to IIc'p the owner decide which

tool.

are MOOed for IhlS lev", o f work. In addition, ~""'S such as an Biectric drill. hacksaw. files.

sold ....iog Iron and a workbench eqUIPped with a vice, may be needed. Although not class«! as 100/$, • selection 01 bo/!$, $Crews, nulS, Wll!Ih\lr5 and pi""e s of tubing always come in usefLJI.

!nft\ljtahly certaln Ia9I<s requi'e the IJM of a service tool. Where poss ible an alternative tool or method of approach IS recommended, but $OnI6\imn there is no optoon If personal injUry or damage to tho component Is to be avoided . Where required, semce tools are referred to In the relevant procedure Service 100II can usua l ~ only be purchased /rom a molorcyde
Maintenance and minor repair tools

-- ,---

1 Setafflil/-bladed

2 Set of PfrIIips '-1

6 SelofTOOIlleysorbils 7 P/ier!l.a;l1etsand

self-locking gnps

3 CombinaI>On opttn.-d 9fldring SfJI'Ilf"IIJ'" 4 Sod<et ",,/ (318 inch or lf2irlchc:i'1l<e) 5 Set of AllIn I<er-l or bits

9 C-spwTnIJrS 10 TtMd dep#! gauge and

""'--

..... --"'"

11 CabItt oiter damp 12 Feelwga<JgeS 13 Sparlc p£Ig gap measuring 1001

16 ClllibrnIfld!fYrlnge,

14 SpwIr plug ~ or

18 Oil dr8iner can or

15 WIllI bnl$II and

19 Purrp

-""''''''''''

-""""

17 Oil Mw itdapllN3 ~,

rwe 01 can

" """'''

,..,"'"

21 SlrWghI-edgetrd 22 Conlinully tesW 23 Satiety chIIIper 24 /-Iydrometef (for baltBty specJfic gnovlly check)

25

AnIi-~/esIer(for

/iq.Jid-cooled engr.s)

Tools and Workshop Tips

REF' 3

Repair and overhaul tools

1

ro.q..e---"

4

(smaJ WId rrw:J.fWIgW.) 2 ~rionII. pIaslc or

5

I'IIImmr.I 3 aoll-t.:.d /rr1pEf _ _

I

-

Vemier~

Cin;J.ip,.,. ~temaI MId lI.
...

s..rolcold~

Specialist tools

,-......"'"

2 TIIIfIIIcq:ling~ 3 0itr1~

10 "

..

wn srnpper WId

""""

-

MIitJmeItw~

MJlI', ..".. WId dmt,I 12 ~/!Of

...........

•

13 Hosedemp ('wInQnut rype shown) 14 CAIIch /'IOdIlQ tool 15 Qne--n..,~dJI!t;h

-~

REF'4

Tools and Workshop Tips •

UH proprietary eoglne degraasera or

so/Vants wnich hava

a rugh flQh-pc>n1, !lOCh

.s paraffin (kerosena). lor cleaning off oH. grease and dirt - """'" ""II pelrOl (gasoIioa) for cleaning. Wear rubber gloves when hand li ng so/voot and ang"'" dogrea_. TIKI /urne$ from certaIn soIvenl8 can be dal1-9flroul • always work In 0 ~venmated a ......

The worlcbench • WOfI< is ~ mkJCh ~ by raisIng the bike up On a ramp· compon«>la mllCh more accesslble If raised 10 waist 1.....1t!. The hydrauli c o. pneumatic types seen In the dealer's worl\shop are a sound i~tm""t If you U"dB""~. a 101 of repal", or ,,~ ... haul& (_ illustration 1. 1) .

.rto

Dust, .ye end hand protection 1.3 This auxl1lary stand attaclM!s 10 the

. wingarm pivot

• Prot act your lungs from inhalation of dUlt particle. by wea ring a filtering mask over the nose and mouth. Many friCtional matedo lB $t,1I conlaln aSbastO$ which II dangerous to yOUf health. Protect you r eyes from spouts 01 liquid and sprung components by wearing a pair 01 protactive QO{IgHiS (sealliust..tlon 1.61

1. 1 Hydraulic motorcy<:1e nomp

• II raised of! ground level, the bike must be suppofted on the ramp to avoid ~ failing. Most

.arnp$ Inco rporate a 'ront wheal locallllg clamp whIcll can be adjusted to suit different diameter 1Io'I)eeIs, When lightenng the clamp , take care not to m ark Ihe wheel rim Of damag& the tyrI.I • use wood block. on each side to prevent Ihl8. • Secure lire bike to Ihll ramp us ing lie' downs (see Illustration 1.2). II the bike has only a sldeslan<:!, and hence leans at a

danll""'us anglll when raised, suppo" 11>8 bike on an au>:illary stand.

Fumes lind fire •

ReIer 10 tha Safety flrst l page al the

t>eginnng 01 !he manual for fuD detaiis. Make aura your workshop II equipped with a lira e~t lnguisher suital:>ll for fual-ralatOO firll!! (Class fire - flammable liquids) - it 15 not suffident to have a wat.".·I'Jed e>
a

Fluids •

If you need to drain fuel from the tank.

slore ~ In an appo-oved contall'\lll" marked as suitable for the slorage 01 petrOl (gasoll""l (.... Illus tration 1.~) . Do not store fuel In glass jars or bonl"",.

1.6 A fire extinguisher, goggles, mask and protactive llloYH should be at hand In tIM! workshoOp

• Protact your hinds /mm contl ct with solvents. luel and oils by w....ring rubber gloves. Alternatively appty a barrier cream to your hands bel()(& stanlng work. II handling hot components or ""ld9, we" suitable gloves to protect your hands Irom scatding

""'

....

What to do with old fluid. • Old cleaning so!venl. luel. coolant and oils shoukl not be poured down domestic drains or orno the gfOOnd. Package the fluid up In old Oil containers, label ~ accordingly. and taka ~ to I garaga 01 disposai lacMy. Contact your local ou!horltV 100Iocelion of such SltM or rInQ the 011 care hotIine.

Note, II is ~lisoclalend

1.2 TIe· downs ..... used around the

/llege/lo dump 0/1 _ n the dnlin. To find the ioc.tlion 01 your Io
passenger footrest s to sec ..... the bike • AUXI li ary (paddOCk) stands are ",fd&ly avai lable from mall a.de< compenles Of motorcycle dealer.; and attach "'Iller 10 Ihe wtIeeI 8J
"umber,,..,..

/n the USA, nole fha l a ny 011 supplier 1..5 U .... an apprO\led can only for $loring patrol (~soI lne)

musl BCcapt used <>II for recycling.

._-

Tools and Workshop Tips

• SIII·locking nuts 61th..- 1\8..... nylon - . or two sp;ng me\aI ~. or I shoulder which ililaked Into Ig'oo.,. In the ahlfl • their advantage over conventional plaon nuts II I .esistance to ~ng due to Vlbratloo. nylon w-t type can be UMd a runbIr 01 - . but must be .--ed """- !he tr\ctlon of the nylon Inaert ill"8duced, Ie when th8 nut spins frealy on !he wll. ~ tab typa can be I'IO..ISed ..... the lato. .., !brnIged at>ouIdereCI type ......1 be r.--.d .-y lime Ills dostllfbed.

..... baII ... rdI

no.

Fastener fype. and application. Bolt. and ser_.

no.

• Fas,...... head types .... "ther 01 hexagonal. Tono; Of apliMd design. MIt. Inlemal and .~temal ¥e<$10111 01 each type t_ illustrations 2.1 and 2.2): aplined head l.at..,.,.

,f,

nol In common ...,. on

motorcyclM. The eor'WSlllOl'lal slotted or PhIllips head d_gn ,. used lor cer1lm

ac._a. Bolt or lere'" length I. alway. measured !rom the und«sIde of the I-..d 10 the end oIlhIltem 1_ lIIusntion 2.111

AEF-S

no.

2.3 Plein "'"'-IA.!. P'""'Y w..t- (8). I9fIng wnt-Ie) .not - . d walher (OJ

•

The spht-rlnll spring washer works by

appty;ng aXlII I_ion betwe.! lhe '85'''''' head and component II tlaUened, 11 is fatIgUed and must be ~. If • pWn (IIaIJ

... -

washer Is used on Ihfll,stener. potlHon the spnng washer between the l"'5t_ and IN

• SplIt pins lconer pins) ..... used 10 loci< I c.steIaIed rut to.1IhIIft orlO~ ~ of. ~ nut. Corrwnon ~ _ ......... ...... _ brake torque ...... BIICau8a the ~ pi1 .... .., deformed to loci< ..-cu>d !he rut a ,-.pi. pro must . . . . be.-l on ir'I:taIaIlon - . . . . . 1iI. h oorrect PIll whoch .... 11 !IIlU\Ify 1'1 !he shaft hole. Maka IlI:1I !he split pro Irm5 _ c:onectIy located around !he nut 1_

1iZII"

~2.5_2.8J.

Serraled lIar type wasl>e<s d,glnto lhe

•

!Ulen« and componenl 1aces. pre~enhng loosening. They .1'fI ollen used on ".cInelli

..u. (wPund) ~ 10 !he frame.

COne type washllra (_"mas called

•

Belleville) .ra conical .nd when tight&ned IIPPIY a>et_ ....... the be !lISl_ inetahd "-I _ _~.

lhe dished sl
• T-'l ~ ..... UMd 10 loci< plain nut. or bOIl. on a shaft. A portion 01 the tell washer iI benl up hard ~ 0Ilt I\at 01 !he nut or boil 10 ptWW>t it~, 0uI 10 !he tab ....... being deformed In UN. I new I.b WI~ should be UMd fNery lime ~ Is dfstllfbed. • W..... w.ahltf'S .... .....,.;j to I.k" up endl\o
2.15 B&nd spill pin (coHo. pin) arma a. shown (arrows) 10 uc,... • cnlellated nut

and pr1IY8nI excasM .... to-~

play of • component. Can be found on rocker

arm ahlIlIa. Nub and 891it pins •

2.2 External Ton. (A), $pIlned tel and hoIugon tcI hosleMrl., with COilespOiidloog aocII_

Convent>anll plain nutt a •• u.u.'1y ....

IIded 1_lIIustratlon 2.4). They ar. JlzIId by Ihr.d diameter and p/tc;tl, High t.-de nutt carry • number on one enod 10 denala their t....... S"""IIth.

• Certain last ....... on the motorcycle heve • I_Us marl
CaUI/on: II tha casl.llaled nul s/ola do nol align with tha .haft hoi. after tigh,.,.lng 1o Ilta lorque Mmng, trgh,.,. lIN nut untillha nul sJof a/igM wdh lIN hoIa - never sIac/r..., Ilta nut to .'/gn lIs

high''''

....

• PIaln washfn IlI'9 used between a I.at_

r - l end. e<>rnpontnl to ~t ~ 10 tile COIT1POMfl! or to spread 1M load w ....... t~ is app4jed. PlaIn waahert can -.0 be used ., Splicer. or shims In certain assembhee. Copper or aluminium plam washerI _ oftS'I UMd .. seeling washers on

-...,.

2.$ Bend spilt pin lcoH... pin) .rm. . . shown 10 uc..... plain nut

•

A-PIne (shaped bite lhe IatIM R), or slop porta as lhey _ .ometJ"'"" called.... sprung .nd can be ,,,ul.o11 th-r ... e OlherwlSl In 2.4 P\.on nut tAl, shouIcMnd locknut (B), nylon Insert nut IC) _ Clltotllated nut (0)

good condtlion. A1wayl Inllll1 R-plns with their closed enod lacarog forwarda ( _ MIUltratlon 2.7)

REF· S

Tools and Workshop Tips

eirel'" 1_ IMustr.tlon 2.81 • ~ ~ c.aed SIlII)-fingI) . . I.ed to reIan componentS 011 • st.t'I Of in • houUIg .->d ...... ClOIT.aponding ext...... or Int.-nal MrS to permit ........,.,... Par....-SIded (mIdIoned) CII'dI!» can be installed erttw way round WI lhelr 9f00Yt'. whereas stamped ~ (whic:tI t.a.... • ct.mt.red 0Idge on ."... 1_) must be In'llI l~ wilh the chamler fac:lng away from the direction of thrust load (see illustration 2.0)

2.10 Align c;"clip Opening with shaft channel •

CIr'C~ps

component. and become 100M In th." II!'OO'I". WIth the .... bBequen, dan9- of becoming doalodged In ope
........,

WiN CIIdij» .... oarrmonIy used as poston pin ra,alnlng chps. II • removal ta r.g II

•

ptovided. long-nosed plllIfS can be used 10 dislodge them. Ol herwise careful use 01 •

Imalillat-bladed sclewdr1vlII' I, neeeMary Wi'e cl'cl l ~ .hould be ,eflawed ellery time t!'Iey _

d",turbed.

dr.mete,. lind pitch

• 0Ia'neI. oIa male tined (screw, bolt or I5Iud) .. the outIicIe d~'" 01 the tn,-*, portion illustration 2.111 MOlt motorcy<:le mIt'Iulact~ use the ISO ~'-tlonli S~ 0r0-n1Hllon) meuIc

,Me

..,..wn~"'~,egM6""'"

e.t_1 .tamped CIr<:Iop (AI, Internal stamped clrellp (8). machined circlip (e) and wI<. clreHp (0)

to 1 8 rnm diImet", ~ . SiaIg ,. the _ 101" IIIltl, except 'I\IIt the thrMd diamat",,. -.nod 100M tlw ""'Iioysof the nul. • PIIctI III the di5Uroc:e '*-' the J*IkS 01 lhe Ihl'Ud (... Illustration 2.11). ~ Ie expteMed In ml ll~ thus e cotrmoo bolt lIze may be «<preseed as 6.0

inc__

~

1.0 rm1 (6 rm1

• Alway. uN clre llp pli"", 10 remove and install clrcl'~: 81tp11nd or compress them lust

thrnd dlamet .... IN! 1 mm pitch). a-a l ~ pilch In propoftioo 10 Ihrnd

enougn 10 remova them. After Installation. rotate 1M c;;rchp In Ita 11_ to 1!nSIJ.... It '-

diImeter.1II\hough Ihwe ... eIwItfI e>
HCurely "'Ied. II malalhng a cin:Ap on I spIined shall . . . align ~ opeIWlg With • wfl cn.nn.I 10 ......... 1M cifclip en<:b . . ",
~.--t--

-

lMI'IIISTlOAO

~USTW"'SH~R

] I

conVlIfllJOI'lll fastener appIicallons Ind the .:companying table CI/"I bel.lSed es a gude AdthlJor-'Y, the AF ~ F\iIUI, _ or IOCkeI sae ~ of the boll 01" nul 1_ IIIuatratIon 2.11) ,. linked to ~ end potch ~. nn.:I pltctl can be ~ with a tined PI\III I - MI~ 2.12)

,~

MG. 1.0

,,~

1.46".0

,,~ ,,~

_ . _ _ .. ..:Msed --t ..... godip

TII,.MI

u

AFme Thread diameler " pilch (mml M5.0.8 'mm

can 011_ due 10 the throat 01

,,~

Mex 1.25

Ml0.l.25 MI2 K1.25

•

The ""'-b 01 most la s t _ .... oItha flgh t..l'Jencl type, !oJ rn.y ... lurned clockwise to IIghillfl end antJ-clockwlse 10 1ooMo. The . . - '~UlJ Ii<>n applies 10 lfIft-hand Ih,. .d lastenert, which are lurned en ~ -cIoci<wIM to tighten a nd clockwise to 100000n. Lell -h,nd th'ead. a re used wh ....e ,otatl on of • ocwnponent mighllooMn, ~ho'lII right_ hand tined fastflnllr.

Seized ' •• teners •

CorrOSion of &l(temal fasteneR due to or .-...::bon betw..-. two dl"IITIlI., mataIt _(MIt I period of _ . II wiI build up toO.,. In _ t contHtionl or In countrln wtJere ..~ ~ uHCI on IhI fOfdl dunng the winter. If • last. . . ,. _..." con-OCIed It ,. Ii....." that "",mal .... Ihod, 01 ..movaI wlR f. ,1 and result In Itl head being Wit . .

'*'

,,,1_ When /\Ii".,

you attempt ,emovlI. the

\tIrtad .rouk! bellelrtl to crack fnIe and uMCnIW _I~ - ~ It doesn't, Itap there before cllmaglllg SO"lIIlhing • A $mIIrt tap on IIlI! head of Ill" tastllfllf WIll oil.. IUCCeIId in breaking t"" corro.ion which h" occurred In the thfeads (sa. Mluatrltion 2.13) • All ..-0Il0l pIIOIIlrlllng fluid (1Wch .. W().«I) ~ the ""'" bfIforetIIrId may wort< III way down liiio the ~ a->d _ fWmO'4I. CepInding OOthalocabon, VCU n'I8y be . . to ..... up " f'\astiane wei ...,....; the ....... r - I .00 iii ~ WJth pe"I8\IlItIng 1k*I.

r-'l'-I

b.'.! Q ,

W · l

- ~ =1

~ StWIP fOO!

cttAMft:ND (DGE

2.1 Comoc't IItting 01 • stamped circIIp

2.11 Fesl_IengthI\.l, lhnMd dll met.. (0), \tIfNd pitch (PI end hNd . . \AI')

2.13 AIIhIrp tap on the head of " fe,l_ will oftllfl breek !rea e c orroded \tIfNd

Tools and Workshop Tips

REF. 7

• It you arto WlXI
Ho_.

Broken f.ste".,.. and dlJfflltfled hettds 2.14 U~ng an Impact driller 10 free • ' ••1.....

• Where corrosion tID, o<::curred between dlS$imUar metals (eg .,.... and alumlmum the application 01 '-I to \he last.... I\ee(f wi! CteIII. a disproportJonaIe expansion rata between th, two metals and break lhe

"loy!.

selzur. c.uud by the corrosion. Wllflther '-I can bII applied dtPtndI on the location ot ItIOIlasI.,.. - any stIITQUfIding components likely TO be damaged muat first be rtm<>Yod (... illustration 2.15). Heat can be applied laW>!! • pMIl stri~ tINt \IOfI or dolt. iron,

or by

im~ng

the

• If thto -"'Ilk at I broken bolt or ser_ " .,;;cessible you can ,rip ~ with MI'-locking grips. llle knufIed whNI type .tvd exlracjor

tool or sel1-gripp1f19 stud pull., 1001 I, partlcuIarIy lIMfuilor I'8Il'OO'VIng tht long sli.ldl which saww Into ItIOI ~ mouth ....11_ of the crankcase at bolts and se.-.ws lrom wtlict1 the /lead hal broken off I'" Mluslnltion 2.17). Stud, can also be IW'rlOV8d by IcJc:kjng two nuts 1000000lher on the threaded tnd 01 the and .... ng • IIPIUV* on 11M lower nut 1_1IIustra1ion 2.18)

d'ameter 01 the 101_ and 0011 to a IHIpIh which will accommodate the extractor. Use lhe largesl alze utractor po8SIl:"-. but avOid leaving too Mlall a wall ttwc:I
..""

walls oulwards

wed~ln~

it In the

casln~

a ~ type extractor II; UNd. ttv..:t h anll-dock.... sa Into lhe last ...... "" it ~ .,...,.,.., In. ~ wiI grtp 1ha 1_ _ ....:IlrI!ICteW •

~

h from the C8Slrlg 1_ Illustration 2.201.

.'ud

component In boiling

we' ... - w... protective gloVfMI to prevlM1' IC8Iding or buma 10 the hands.

1/ a taper type eMt/Klor II; used. tap it Into

tha

Int~ar

P'*oca.

so that

II

Is lirmly wedged In

u..cnw 1ha 8lItractor (allU

cicci "tMj

to dnow Iha last_ OIIT

Warning: Slud a.\"l,..clol'1l .,.. 11'8<)" Mrd end may bfNk off In If car. /I' not • ask an WlgI"..,. aboul sparlt ..-oslon " Ih" happen ..

I'"' ,..,_

• As a last resort. II 'I POSSI~ to usa a \IarrunIIr ..-.d cold chIaeI to worI< ttle laslenef tlead unscrtwed 1_ Ulu.tnltlon 2.1$) This WIQ damage the lasl_. but mora 1nportantIy...- cara mull be lakin not 10 dIIrnage the tum:>unding cornponan!.

2..18 Two null can be locked tog.ther to

unsc. _ Caulion: Remember thaI the component bafng Neurad Is ganarall'y 0 1 _ If8hJa Ihan the boll, nul or IC,..W • wllan Ih. r.ltan..- I. freed, do nol unscrew It with fon;a, InJl.ad wont Ih. fll.'."ar back and fortll whan realalanea ,. fe" 10 ~I Ihreadda~

a Siud Irom I componenl

•

A. bolt or &eraw wNch has broil... off below or laval w"h \tItI casing must be .xtracted ualng a scr.w exlractor MI. Centra punch the la$lener 10 ce-ntraHsa the drill bli. then drill I hole in the lUI.,.,.,. lIIu.traUon 2. 19). SaIact I dri" bit WhiCh Ia appro~lmately hall 10 three-quarters the

,s..

I._

• AIIerna1lVe/y. the broken boItIseraw can be drilled OUI and the hole ratappad lor an oversize batt/screw or a dlamond-'actl(m thread Insart. ~ it assentiallh9t the drilling Is carried OIIT ~ ....:I to 1ha c:orract depth. olh8rWlsa \he casing may be rulnad - II In doubt. an\rvlt1ha WOI1I 10 an eng~. • BoIt,..-.:I nuts with rouocIed COI'Il8I'3 C3UM the c:orract IIze ~ or .ac:kello IIip when

_1IPPhd.

Of the typea oIeplR"l8rl3ockfll available always 11M a aax'poInt type rather than ., 8ighI or twfIIva-pollll type - better gnp

Ioroo

REF. S

Tools and Workshop Tips

I. obtained Surface drive spa......-s grip t"IIlddIe of !he hex 11m.. ralher tt.n !he o;;on.." Mel _ tI'g good In ~of ~ l...I_ ilustntlon 2.21) • SIotted·head Of Phill,ps-head sc......,. are 011., damaged by 11M I.e 01 the -ong ~ screwd ....... AlIen·head and Tonc./wNOd screwl arB mucf1 len likely to SUltain

dlmage. If enough of the KraW head "

2.23 A thread repair tool being uNd to corNel an aIlemal thread

2.2!1 To Inltell . 1hrea-d InHf"t, first drill out the origInal hINd . •.

chasen ar. ava,lable tOf &pari< plug hole threads. The 1001 wi!! no! CUI a new thread . bul clMn and lrue the orIglOal ltnad. Make sure lhal ~ lIM lhe correcl d,a-netet and PIlch 1001. S,milarly, ,d..."", Ih,MdI cen be cleaned up WIth a d~ or a thread rwtortll" file ( _ lIluatrallon 2.24)

expo$OId you can UN • IIIK:k$IIw to cut • $IQI in ~s t..-I lind n.... ..... con~iOnIII n.t-

bIIded

~

to

...-.:MI ~.

Ailermot,vtIy

'*' a hammer and cold chisel to lap the IIead 01 thoI /•• , .......

arourw:l

to~"'"

it.

Alw~

repI_ damaged t ..,...... WIth new onM,

Pf$ferably Torx or A11en-hMd type.

· II.

poesIbie to driI out tIM old ttwe.I and

noI4p the

A dab of ... hla grinding compound lIetwa.n !he scr..... head and Be", ..., driver rip wIN offill! (Jlwlil good fIrlp.

TPlreM1 repair • Thruda (paIticularty thou in alumlnoum aUoy components) an be damaged by ov.thghtenlng. beong assembled With dirt in

1M th'Ndl, Or from I component Working 100M and vibrating E-'tuaIIy !he ttn.d wiI lad completely, and it w~1 be ImposSIble 10 tlglllen the fast_ • II a thread is damaged or cJowed with old Iodung c:ompoood It can be fWlO'I/8Ied with • th,nd .epa... tool (thread chasefI [_ Illus tratlona 2.22 a nd 2.23); spec,a l th'ead

cornponan to the nul _

slzl.

This win work where tMlra II .... ough Slmoundlng mattrial and • new ~t or $Crew can be obtained Sorneum.. howeYer, 001 pouibIe - well n W'Ilere the boIIISCJeW pan,. I hI"OlIQh ano1h" compOn,nt which must . Iso be suitably modIfied.•Iso In casee whent a spao1< plug or of drain plug cannot be obIaned In • larger
this.

.

~

, "..-

-

'/~ ,.'

V

; •

2..29 . •• IIOd ttn..t Into !he component •••

The diamond-sect/on Ihread Insert (otten known t.." Ill< fXIPIhr tract. nama 01 HeII-CoN) ill • ....-npIe and .tfeetive meIhod 01 - - . g the ttvwd and ~ the originIII..a. A kit can be pu,chased whIch contl lns the ta p , Insert and Insh.IUng tool ,... lUuatrutlon 2.2$). 0rtlI out the damaged Ihraed wilh !he II'H drill apacII\ed \He ....tratIon 2.2ISI c..IuIy...., lhe thread (I . . Illustration 2.21) 1nslall the •

w-t on the Ins!aIIing tool and ttvwd rt ~ Inlo plac, using a light downward p'lt$Sura IIlultratlonl 2.28 and 2.211) When pos#liOned beIwewI. I'. and 112 tum tIeIow the eu1_ withdraw the Ins!aIIing 1001 and use the br .... k-olllooi lO press dOwn on the lang. breaking ~ oft jaM Mluatmion 2.30) • There are epoxy IIv-:I ~ kits on the mlUltal whieh can l&build llriw-;:l Int...., th' eads, altho ugh I hl. repai' Jhould fIOl be ..-d on high Iotd·~ components.

ISH

2.22 A thtNd repair tool being used to correct an Internel thread

'0 _

2.25 Obtllln, \hrQd Inter! kit to ",i11he thread d~""'t .. and pilch required

Tools and Workshop Tips Thread loclffng and _allng aJmpounds • locJong COI!\pOI.o'I(tI..,.-:I1n ~ where the fastener is prone to IooMnong 00. to v,br.Uon or on Important safety-related ~~ whoch might cause loss of control of the motorcycle II they Ia.!. It Is also uMd where Important ra.l..".. cannot be HCured by

....

oUler me.ns such as lockwa!Jherl or .pHl

• Before appto,TIg Iockng ~, make ..... !hat tht ItweacIs (1m...... and ~ .., ~ and dry 'I>'I1t1 .. 00fr'JP0I.nd rerooved. Se40ct a compound to aurt tile eomponent being secure
'*'

~I..-noval.

• Certatn I U I _ ere ~Ied with " dry film type coating oIlocIoog compound on their thread. Always rene", this type 01 fastener ~ disturbed. •

Anti_ .....

compound.,

.au<:h . . coppet_

based ~, can be applied 10 protect threads from Mizufe due to exlrerrot '-I and co"osion. A common Inatance Is ,park plug tlneds and ..maost .)'at..... last ......

F_/er gauges

• When measor1ng I cJearanea. &elect I ga.oge wtIch • I iglt IllidIrciJ lit ~ the two componIrIIa. You ITlIy . . . , to .... two ~

Ioge!t"8- to " - A the ~ 1ICQ.r"Ite/y.

Micrometers • A 1TIicromet... is a preasion tool capable of ~ to om Of 0.001 of I ~ It ahouId always be stored In ks <:aM and not In tile general toolbo._ It must be kept clean and ney... dropped. ottlerwlse k' 'rime Or ~ ..,ria could be distOf18(1 l"MUItong .. lneccurl~ readi'lgL • hternll micromaters are USed fOf meas.uring outside dlametlln of components .-.d have many more applications IIIan inttwnaI micrometers. Mocromelers are Ivallab!!! In dIfferent slza ranges. ag 0 10 25 mm. 25 \0 50 mm. and upward. In 25 mm .tepa; some IargII micromelln have Intert:hangeable IInY'is \0 aIow a IWlgfI of ~Ia to be ~ Generally !he Iar~ precisocn ~t you are likely to toe on a motorcycle is Itla piston diameter.

• lnternaI ~ (Of bore ..-.;:rcometersj . . ~ lor -.ring ~
--.

External micrometer Nota:

T".

COIlllftnllonal aM/agua typo! hsttur!wIf Is describad. Mhough much easier to /Md. difJI'-' trtfcrotn$~ are ~ • Always ctleck ttle <:ahbration 01 ttla micn:>meler before usa. With the .......... closed to 25 ITW!I type) or MIl a.- a leal gauge (!of

~

3.2 Check mlcr-omater calibration

....~-

II"Ie larger ~) !he ICala should read zero ( - ill... tretIon 3.2); make sure ItIat the IInY'is (WId t8:lt piece) are clMo tnt. Nrj dIacrepancy can be adjusled by .-.f..mg to the nstruct.c.ne; auppll
'*"

Don·,

..""'*'.

• The micrometer Is read by relerrlng to Ille the - . . WId the ........... tcaIa on the thornble. Read off the sIMvw IIrst to obtain the base measu.........,t. then add the line measuremern from the thlm~ to obtain tile overall reading. The linear llC:ale on ttle sleeve ~s the ~ng range of the mocmmecer leg 0 to 25 ~ Tho annular saoIe ~ ocaIe 011

• Feele. glull8. (or blades) are uled lor mus.ufinll lmall gaJa and claarlncM (1.&8 lIIuatratJon 3.1) They un also be LIHd to measure tnd'Iloat (sideplay) 01 a component on I shalt wtwa 1ICC9" Is not possible with a d'IIQII"ge

• Feeler ~ Mia should be treated with Cllfe and IlOt bent Of damag«!. TMy are "'chad wtttlltleO' s.i.za on one 'ace. Kaap lhem claan and vary IIgtltl y oiled to prevent C(Im)Sion build-up.

3.1 F..... pugH .... UHd for menuring ..nail ~ and c:IeanncH - thlekneM is ma.... ad on one lace 01 gauge

REF. 9

,,

.... ......

3.3 Micrometer compo....,t part •

3 SpjndIa •

f'q1Chel

5 F_ 6 LodIfng ......

Tools and Workshop Tips

REF· ' 0 on

U. II'IImbIe win be In graduatlOOS of O.Q1

nwn (or ..

marked on

11'4' Inama) • one lull

revoII.Ition of the tlWnble will Ihe 111lH.

~

0.5 ITYI1

on

Kale. Taka the ••adlng whe.e th"

datum line on the sleeve Intersects Iha th,mble'. scale. Always position the eye dltllCt/y "bow lhol ItCaIe 0 1 " - - ." lnacanta ~ ...... r...oII. In the eKample shown !he Item melISIJ.8S 2.95 mm (see Illustntlon 3 ...)

Unea.scale

2.00 mm

Amularscale Total fogure

0.50 mm 0.45 mm 2.95 mm

"",",""

3.5 Mlcromet... reading of 46.119 mm on

linear and ........... -'as ...

3.7 ExpIond the lelascoping f8U9f1 In \he bor., lock its poaitlon ...

3.4 Micrometer.-..dlng of 2.95 mm ~ mIerometers haVII " locking IfMIr (6) on IhCII'rame to IlokIIhe setllng In place, allowing the Item 10 be removed from the micrometer.

•

Some micromete<8 have II Y.,..n ie< scale

on Ihal. aleeve. providing an flyan Imer ,.,... .....em.." 10 be takan, In 0.001 Incrementa 01 8 millimetre Taka the sleeve and thimble measurement .s described aboy" II..., ct>eck whleh graduation on the

vaml ... leal" aligns wIth '''''I ol\ha annular scal' on the Ihlmble Not,: 11're eye must be p8tpendlculBr 10 rile scale will", taking Ilia ~ tNding - "~rotalfJ the body of rhe mIcromerer ro -...... this. Multiply the ___ teale IigIn by 0.001 .-.:I add It 10 the bMe and line ~ Hgtn..

In lhoe example ehown lhe Item measures 46.994 mm (see Nlustr8tlone 3.5 and 3.6)'

L.--.. 8CakI
46_000 rrrn 00_500mm 00_490mm 00_004 mm

Total,*"

46.994mm

~

seal .. (base)

,--

Amu_ ecale (fine!

Intemal micrometer •

Interl\llt mlCromet........ a~allab~ lor

n-..Ing barto dl8I'"IWI..... but lire e~pensiYe ...:I urII<eIy to boo ........ lor home use.. It .. suggeettld thai a . . of t-.copng gaugee...:l SIT\III holt gauges, both oI-MIieh must be 1.I$tId woltl en eKtema! micrometer. wilt suffice for tal
measure inter"*' diameters of eompOnttll$. Setect a gauge with the con-ect alIa ranga, make sure Its enOe are clean and insert Minto the borll. EKpand tha gauge. thlln lock Ita posotlon and Wlth-CIrlW II tram the bore (SM lIIualraUon 3.7) . MOilsurll across ,he Q8l>Q8 ~ with a mic:romeIer ( _ mU$tratiQn :UII • Very small diameler boree (auch ........... guidee) _ .-...:1 wrth • small holt QIUQt. Once adjusted 10 a ~Ip.fit Ineld. the component, III poIIUon II locked and the gauge withdrawn for me!lSurttmen\ wilh • mIcromEII« ( _ Wlultratlons3.9 Ind 3.10)

Vemier C
3,11 Expand the smalt hole ~ In the bora, lock its potItlon ..•

lines up .xactly with any of the dlVlaKlnl on the maIn scale. noting thai the dl~isi""$ usually represents 0.02 of a millImetre. Add this fine musurement to thtt base ~t 10 obta.in \he total reeding

Tools and Workshop Tips

REF·"

Pfastfgauge

3.11 Vernier component parts Oinear gaugel 1 Clamp sctews 2 &t8maI jaws

InllJmBl iaw$

4

Thumbwhool

In Ih
Sliding scale 6 Main scale Base measurement

Fine measu,,-'

55.00 mm 00.92 mm

Total figure

!I.!I.92mm

• Plast.gauga is a plastic material which can be compressed between two surlaces to measu", the oil clearance betweal them. The width 01 the compressed Plastigaug8 is measured against ~ calibrated scale to delernllne I~ clearance. • Common uses of Plasti(jau(je are for measuring the clearance between crankshaft journal and main be~ring in~ert s, between crankshaft journal and big-end bearing inserts, and betw~n c~mshalt and bearing surlac"". The lollowin !j example describeS big-end oil clearance mea~1. • Handle the Plastigaugtt materiel cartllully to prevent di!.ltonion. Using a sharp Im!fe, cut a length whid! corresponds w~h the wklth 01 the bearing being measured and placa it carefully across !he journal so llIat ~ is parallel with the shaft (see illustration 3.15). Carefully install both bearlng shells and Ilia conoectH'lg rod. Without rotating the rod on the journal tighten ~s DOlts or nuts (as applicable) to the specified torque. The connecting rod and bearings arB then disassemb led and the crushed Plastigauge examined. "....,...~

Some vernier calipern are eqUIPP\'d with a dial gsll{ltl lor fme measurement. BelOte use, check thai the jaws are clean, !hen close It1em fujly and ch8ck that th9 dial g;.ruge reads rem. If necessary adjust the gauge ring accordingly. Slacken the vernier clamp screw (1) and set ~s jaws ov8f (2). or Inside (3). the Item to be mellsured l:HHt illustration 3.13). Slide the jaws into cOl1lacl. using the thumbwtleel (4) for

3.12 V ...ni... gaU{ltt ..... ding 01 Sli.92 mm

fine movement. Read off the main scale (5) where the edge of th" sliding scale (6)

3.15 Plastigauge placed acrossshaftjoomal

Inter..ects ~. taking the who .. number to the

• Using the seale provided In the Plasti(jauge kit, measure the width of the material to det...mine tha oil clearance (see Illustration 3.16). Always ramova a ll traces of Plast>gaUlJtl alter use using \'OUr fingernails

lett 01 Ihe zero: this provides Ihe base

measurement. Read off IhfI needle position on Ihe dial g8ugll (7) scale to provide th& line measurement: each dMsion represents 0.05 of a millimetre. Add thIS Me measurement to the base I1'l(la$llfament 10 obtain the tolai "lading.

In the e~ample shown the item measures 55.95 mm!see Itlustrallon 3.1.):

BaSIl

m8~suf t)ffilm!

Fine measurement Total figure

1 Clamp scrow

2 &!emaI jaws 3 Internal jaws 4 TIlumbwheei

Mlljnscllie Sliding scale DiIllgauge

3.14 V..... ler 9I'U98 reading of 55.95 mm

Caution: Arri~lng at thll cor,..,ct clearance demands that the assembly ;. lorqulld correclly. according 10 the setlings and sequence (whe,.., eppliceble) pro~lded by Ihe motorcycle manlifacturer.

REF' 12

Tools and Workshop Tips

01111 gllU(Ie

or on

(Of.' T••t IndlClltor) " A dial gauge can be used to accurately ~

smaIlllmOlJnts of~!. T~

1,15<'18 are meuurlng shah ",nO<.lI or shaft ($Idf.IpIII)I) and setting piston pOSItion kif ignition lW'1'W'1g 011 two-strokM. A dial gauge

~t

Ht kJSUIIlty comes With a rang. 01 d'n....,' ~ r.dadaplws IWld rllOUllIng ~ " The ga~ needle must point 10 zero when I, ,.., Aotate the ring MOUnd its periphery to zero the g.auge. " Check that \he gauge. C8!MbIe 01 ~ tile utent 01 mo~ement In tile worIl. Most g.augM have • small dial SOlI In the , _ whieh rec:ordlI whole millimetres 01 r'I1OY$"I'*lI as well 8$ the II .... scale around the lacl perip/'1ery wtIich ill QIIbaIed in 0,01 rrm ~ FIud ot! the .....11 dial fin" to obtain the base ..--...nwnt. IMn IIOd lflii ~ from the fine.:ale 10 oOIaol the 1ObII....:ti'Ig

mlllliml,lm ltI'ugl .... dlflll as lhe amounl 01

rullOlJl In I.,. ."-ft. Nota: n,. ,.,;J,ng obtaill&d wdll)e 10'" runout ", ,,,., point· $Omit tmIfl(J!aelu"'" lpfI<;ify fhal fhe runou/ firr.Jre j$ ~ 10 compere wilh tmIr specified ItR!Q(I/ limit. " Er.dIk>at (oidepIay) ~t ,ltquitN that tile g8ug, i, mounted securely 10 the su .... o..md'ng eomponenl wrth ,ts p
011 pressu,.. gaug. • An 011 pressure gauge Is used lor measuring anglne 011 ~ .. _ MOSI ljiIIuges come with a set 0/ adapt.,. to fit the tt>reed 01 the take-otl pOOt (see lIIustntlon 3.21). 1I:he take-ott point o.peclfied by the motorcycle maoulllCl\Jfel" II an •• t&mal 011 pipa union. make :wra that the specified replacemenl UOIDf1 is used 10 ~ oil at.vabOO.

In the examp'- shown the gauge reads 1.48

rrm (_ Illustration 3. t 7)

A diallJlluge with 8Ultable adapters can be used to clelenn' ... piston position BTDC on tfooo.stroIIe engm.klr:he ~ 0I9VbOn timing. The ""-9', .oapt.1nd ~ t.Igth

"

probe _

installOld .. 1M place of 1M

~

plug aoo lhe gauge zeroed at TOC. II the p!SIOO poeIlion iel!)8Ci'ied as 1.1 ~ mm BTOC. rotate the qtnot t.:I< 10 2.00 mm BTOC, thel1 sIowty lorwarda to 1.1 4 mm BTOC.

Cylinder compression gauge. 3. t1 Dial gauge ,aadine 0/1.48 mm •

/I

~

shaft runout, the shaft musI

be supported In ,,"-blocks and 11\& geuge mounled on a staoo parpeodlcular 10 Ihe ahall R"lthe lip of Ihe gauge against the cenlre 01 the shaft and rotale lhe shah aIowty whilst watching the gauge reading llaa illustration 3.181. Take saveraI measurements along the length ollhe shalt and record Iha

• A comprflaion gauge Is used lor measuring cytlooer comprassion. Eilher the "'bbet-cone type or the Ihreaded adapler type can 1)& ......:I. rr. "Hili" is pralarr.d 10

'*

enSute a per1eel _I against the cytlnd« head. A 0 10 300 (0 10 20 e.1 type ""-9' (for patrol/gasolIne angInas) will be aultabla lor rrotorcydet.. • The $paIi< plug ~ rwmoved and the gauge either held twd &gIIInsl the cyIQ:jer heed (cone

typal or the gaug.. .o.ptar screwed Into the "-I ~ typal ilustntion CyInder compression ~ . . - n d with !hoi engIfIe I\.nWIg a... but not I'I.Wrilg - CMY out the comprwaion lasl as desc:titMd In cyIQ:jer

3-201.

esa.

• Oll~. is ~rad with the ~ ",nnlng (al • specific rpm) .00 often lhe manufacturar wiI apKIfy pr&I$lMlIlmiIs lor • cold Ind Ilot l!l'lglna.

Stntight-edge and .urface plat. •

II checlllrllil

the gaskal

face 01 •

com~11or warpage. place. sIN ",Ie or Pl'tlClsion stra~-edge IICfOIS the gasket lac. aoo measure any gap ~w"" the stralghledge and component with leeitv" gauges (see Hlustnotlon 3.22)- Check dIagonaIy 8CrO$$ the ~ and bet--. mountng holes ( _ ~3.23).

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REF· ,4

Tools and Workshop Tips

Ihe Join! will be held evenly and will not be distorted. Important joints. such 81 Ihe eyllnd« head and big-end '8",1_ often hive two- or IhrM-Sfa!;Ie IQrqua !MIlt""",.

Applying leverage • IJM 1001$" the oorr.et angle. PooaItlon • .acl\eI wrenct1 or span ..... on the boIVnul so That you pull It towards you wher1 Iooeef1lng. If this can" be done, push Ihe spanner without Ctring yow fingen; ..-ound ~ lsee Mlustmlon 4.8) - the spanner may slop Of the la.,ener

loosen suddenly, resulting In your being crushed against a component

4.15

ling.~

• The same equipment can be used 10 Instill beanngs. Mike atJrti the bearing houUng is aJpported 0f1 wood bIockI and IinII up the bearing In ils hc:outIng. Fit the bearing as noted on removal· generally they are Installed with their marked alde fa<:ing outwarcla. Tap tha boNring ~uarely Into ita housing I.ISing a ~ or ..:>eke! wI'kh ~ only on the beerIng's outer race - contact with tha bearing t)a llslrOIl.... or in ner race will destroy ~ 1_ illustrations 5.1 and 5.21 • Check thaI Iha baanng inner rac» and balltIron.. rott.la freely.

off a gear nil for example. you may haW! to locate !he puler behind a gear pWIion of !twa is no acc.. to the race and Ihw the gear pnon off the ahatt as -a (sea Mtustratlon 5.4).

Caution: Ensure rha' rhe pu""'s cent,.. bon Iocar.. ucura.fy -oair>ar the end of

".. shaff and will no, slip"""" P"'~sura I. applied. Also Imlure th.t pul. da.s no, damtfgtJ fhe shaff Imd.

nyou"",~on_~to

Iooe«I a fasle!w", push with yow hand open Addillonai leverage Is gained by eMlendlng the IwIgIh oIlhe lev.... The bwl w~ 10 dO this is 10 we • breaker ~ ins'.-I of the reg .... length 1001. or to slip. length 01 tubing over the end of the t.panner or toek!tl w.-.neh. • II additional leveraga will nol work. 1M l u t _ hNd I, BOther d~ 0' firmly corroded in place (see Fast8rnets). •

5.1 Using a beating driver against the bearing'. out ... raea ~--

0-

• Op&fate the puller to thaI Ita centre bolt aKarlS pr-..ra on lhot .naft 0IIId and draWl

the bearing off the shaft. • When Installing the bearing on the shaft, tap only on the bearlng's Inner rae.. contact with the baII&IroIIars or out ... race with _troy the beaNlg. Use a IIOCket or Iangth oIlUbing . . a drift whICh fits over Ihe sh.ft end (sea Illustration 5.51.

Searing ,..moval end Inst.llatlon

DriY.,. and sockets

•

Selor. removmg a bearing. always mtp«:1 the cuing to see whICh way It must be dnyen Oul - _ eUlngs will haVII retanng plat. . or • cast Slop. Also <;htd< lor any identify!nQ markings on the bearing and ~ Insl.l~ 10 a certain depth. measure this at thIt stage. ~ roller ~ _ SoMIed on

f>\jJler. and slide-hammers • Whera. bearing is pressed on a shaft a puller will be required to eKlract It ( _ illustration 5.3). Mak, lura that th, puller cQ\mP or "Os lit securely t>ehind the bearing and are ooIike/y to slip out. If ~ a bearing

5.5 When Instaliinsl a bearing on • shaft use a piaC» 01 tubing which buno only on

-"".

one SlOe· lake nota 01 the onglnal fitted • Bearings can be driven out 01 a clling using a bearing driver tool (with tha correct .aa hud) or • IIOCket 01 the comoct dIamat8' Seltoct the dri..... l'Iead or tocket to that it contscts the OUIer race of the beartng. not tile balb1ro1lers or Inner race. AJways aupf)Ort the casing IIIOl.nd the bearing housing WIth wood blocks, olherwlu lhe<e ~ a nsk of InIeture Tl1e bearing Is drtvwo out wIIh a few blows on the driver or socket Irom a heavy millet. UnleM accnt Is Se\I..-./y restricted (as with wheel beallngs), a pon·punch Is not ,6iXIOirii.ided lilli_it IS moved around the bearing to keep It SQuare In Its tIoosing

the bearing'. Inner rae.

5.3 This bearing puller clamps bahlnd !he llearing and pressur. is otppIied to the shaft end to draw the bearing off

• Whera a bearing locates in a blind ~ in • casing, It cannot boI drM!in or puItod out .. dascrIbed above. II !!lode-hammer With Imi!.. edged baanng puller .ttachment will be rsquired. The puller attaclunanl passas Ihrough the bealing snd wtlert loghlenad IlCpands to lit firmly behind the balling ( _ illustration 5.6). By operatong the slidehammer part 01 the tool thfo bearing 15 lan.,;l out of 113 housing (sea illustration 5.7). • It IS poastoIe. Wtha ~ is of reaonabIe weight. for II to drop out 0' its housing Wthe casing is heated as dMIcrIbed opposite. ~ thl5

Tools and Workshop Tips

REF-15

Temperature change

5.g Drawbolt component parts assembled on a susp&nsion erm Bolt or length of Ihreaded bar Nuts W~sher (e~tema! diameter grealer than tubing IntemaJ diamelerj 4 Tubing (intema! diameter sufficient /0 accommodate bearing) 5 SuspensJon arm w.tl! be8ri11g 6 Tubing (8)Ct81T181 diarnetel" slightly smaller than beating) Wash« (<wama! d~rgr slightly $mW/ar than bearing)

• IIItIe bearing's outer race is a tight fit In the casing, Ihe aluminium casing Can be heated to re l&ase its grip on the bearing Aluminium will eKpand at a grealer rate than lhe stool bearing outlll" race. There are several ways to do this, but avoid any localised extreme heat (such as a b low torch) aluminium alloy has a k>w meltiog point. • Approved melhods 01 heating a casing are uslog a domestic oven (heated 10 t OO"C) or Immersing the easing In boiling wallll" (..... illustration 5,121. Low lempttralure range localised heat sources Such as a ptlint slri~ heat gun or clothG$ iron can also be used ( ..... illustration 5.13). Alternatively, soak a rag in boiling water. wring It out and wrap ~ around

the bearing housing. Warning; All of these methods require care in use to prevent scalding and burns to the hand$. W ..... r protective gloves when handling hot components.

5,7 '" attacll the slide lIemmerto the bearing puller method I~ 81!empled, firllt prepor• • work surlace whk;h wi ll enable Ihe easing 10 be tapped face down to help dislodge !he bearing - a wood surlace i$ ideal since It wi ll not damBge !he ""'"ng's gasket su1ao::e. Wea"ing prot8CIive gloves, tap tile hoated easing several times against the work surtace to dislodga !he bearing o.nder ~s own wt!ight ($f!
5.8 Tapping a easing face down on wood blocks can often dislodge a bearing

5.10 Orawing _ bearing out of the suspension arm • To eKtract the bearinglbush you win need a long bolt with nul (0( pjeee ot threaded bar w~h two nuts). a piece of tutMng whO;h has an ",temal diameter larger than tile bearinglbush, another piece of tubing whlcll has an eKtemal diameter slightly sma ller than the bearing! bush, and a selection 01 washar$ (see Illustration. 5.g and 5.10). Not e that the pieces of lubng mU5t be of thu same ieogth, or longer. than ItIe bearinWbush. • The same kit (without the pieces of tubing] can be used to draw the new bearlnglbush back inlo place (_llIustr.ltion 5.11).

--.

• Bearlngs can be Installed In blind holes uslng !he dri_ or socket method described

• If heatong tha whole casing nole that plastic components, such as the neUlrel switch, may flUffar - remo~ them beforehand

Drawbolts

• Where a t:>eamg or bosh is set in tile 9'j'9 oj a component, SUCh as a suspenslon linkage arm Of connecting rod small -end, removal by drift may damage the component. Fl.W1hermore, a robber bushing In a shock absorber eya C8JYIOI successfully be 00ven out of pOSition. If access Is available to a engineering press, tile task is straightforward. Wnot, a dmwboIt can be fabricated to 8>Ctract the bearing Of bosh.

5.13 Using a localised heat source to aid bearing removal

• After healing, remove ths bearing as described above. You may lind that the expa.wOr1 is ....lIie'''''t for t"- taaring to lall out 01 the casing undar ~s own weight or with a I~ht tap on the driver or sockal.

5.11 Installing a new bearing (II In the suspenSion arm

• II necessary, the casiog can be heated to aid bearing instaHation, and Ihis is some~mes the recommended procedure If the motorcycle manufacturer has deSigned the housing and bearing lit with thIS intention.

REF- 16

Tools and Workshop Tips

• Insllll\ation at bearIng8 can be eased by placing !hem In I IrNler the nighl InsWl"IOIl. n.. It'" t>eartng wUl cootract sligIttIy. allowing..,. w-tIon in iIs housing ThIS IS ollen UMf\II when Installing sl-.ng ' - I out ... . - In me trame.

bel,,,..

~ /' ,.- I . ,"

Bearing typ.. and marlrirJfls PlaIn.n.n~. ball beamgs. needle roU", bearings Md tapered to*" bearings wit! all be found on mot~yelP !_ liIu!rtrlltiona 5.1. and 5.111). The ball and roller types are

•

5.18 Typical beanng marltlng

=~I~C~::'x:::;bea:;;.ter BHrlng fault "nding

$.18 Example 01 ball journal blaring with <;Iamagad baAa and c.gaa

,--,-....

....-..

•

II . beatIng OUter .ace hu spun in III hooalng, tile I\ou.mg mat.naJ win be

~. You c.n UN • ~ locking c:ompOUnd \0 band tI'III out. ractI In pIac. II ~.nclIOO-'.

• Shell bNrIr9 wiliail d .... to dar'naQ8 01 their worklng aul1ac., as • result 01 lack 01 II.b\eIItion, COf'T'CIU:H1 or abrasr.. ~ in the ~ 1_ IAu.,..lIon 5.17). $ma/I ~ 01 dlrl In tha oH may ambed In the bearing material wI\er6M larger partk:Ies wi score the ~"II and shaft journal. If a number 01 W>ort jou rneyl ••• madl, Insuffic ient hf!al will be generated to dove oft condensation wtlieh "'built up on the ~

5. I II Hold outer r1tCe and lIalert to Innat race whln Sf>UI'1

...-

I'IClI with

the otnar hand (see IllustnlUon 5.111)

The bearing ahould be almost a i*,l when

1Il\.IO;. ~ gratt'ltor ra\tJII:s It is worn .

Oil .-.J

remo".' .nd in.t.II.Uon

• Oil ..... IIhouId be renewed - V t..... I oompon.-rt Is dismantled. Thia .. '**- the .... lIpew4ll_Mltothe.....-.g ...... _

not r--.sarity reseal. • OH _II can be priaed out 01 position .. alng , I..ge Ilat·bladed screwdriver (.&1 111 .. II,atlon 8.1). In til, case 01 Crlnkc... _~ check tnt thel the seal Is nol lipped 00 till Inlldl. preventing ill removal wllh the crankca_ joined. 1Ind~.

• Shall bearings {often called In""., ara usua lly lound II the crankallalt main and ~'''II

rod big-end where they _

good

at copWIg with high 1oadI. They are made of. phosphor-bronze matll
with MII-Iub!1caung~.

• a.1I beal'1fIg1 and needle roI. . bQri"llS COOIi5t of • ~ ....... ....:I QUI...... w'Ith IhIo balla or roll.,.. belwMrl the races. They '*I..... conslam 1utJriu,11on by 011 or 11_ and ... good 81 copong with axlIoIloads. TIIf* 1"01.... bNrI~ conaill 01 ....... HI in a t.,...:I C¥ HI 00 the n.. ~ the out..rac.1s MPMlIa. n..y ... good at coping with IllIiaIIo.n ..-Id ~ t mov.nfIIlt along the ahaft - • tyPICal appk:ation 11 In Ihe $I~ng

.....

• Bearlng manulacIUf..-. po-oduea bearlngs to ISO lize standards and ,\.limp one ,...,. of the bearing to lndio;a'l blnt""" and external diameter. load capacity and type I.... 1.... lnItlon $.1$1. • Metal buallM If. usually 01 phosphorbronze matllf\al Rubber oo.t.. are used In SIJIIPWII'OII mount"'ll tva. FJ;n btJst.- haWI .... t... .-d In ItapII'ISIon pivots.

• BaH and roIIr '-""lIt willa due 10 lack of lubrlcatlon or damage to the balls or roI!efs. Tapered-roller bearlnga can be damaged by ovll1oad lnll III....,. Unlll'S' Ilia bearinll I, .,aled on both aid .... wasil II In paratllo (I<eroe«la) 10 remova all old grease than allow It 10 dry. Mak. a VISUal inspection ookn\g to denIed bIoU, or roIters. damaged cagH and worn or pitted _ ( _ illustration $.181. A t-I---.g <*lbec:hec:lled lor_by 10 _ ...m.n 1PlJ"I. "'Wt a 11m oIligtIt 01 to the bMYIg lind hold It c*- 10 the _ - hold w+th one hand ..-.:I spo'I the ImIf the 0lIl..- _ •

~

8.1 Pri.. out 011 seall witt! a larlll flat-bladed o.crawdrlv ... • New ........ "wally Installed with their marl
,-.d. u...

Tools and Workshop Tips Use I bearing driver or socket whICh only or1 the out.. hard edgoe 01 the Mal to nstaliit in the casing • tapping 011 the !mer -9 ..,1 ~ the,..w,g lip. •

~

Oil seal types and markings • 001 _ ... u_1Iy 01 the .,ngIoI-bppild type. DoubIIt-bpped ...18 are !ouod where • roquM;! or gas I, on both Ildes 01 tho joint. • Oil _ can harden lind .... their uaIing abibty II the motOfC')'(:Ie has been in Ilorage tor along period -,~ is the ontv lIolI.rtIOl1. • 011 _ I m.nufact ........ allO contorm 10 1M ISO markJngs 10< - ' .'" • IheM ..... moulded intO the ""Ier fltee 01 11'111 !I8II1 1_ Hlustnltlon 11.2)

REF· "

1m~led It! III ",rface o.f".. applying additlOOlll seaJanl • ....".., ~ a maka SlQ ~ ~

....,1.

.... l1abla 11>1' thlt appliCIllcon. partlC1Jlarly II being applied In a high·lemperatura QfH or In lhe vICinity 01 lull. Certain manulaclUfetS produce MIIIant8 In eiIhar dear. ai"- or bIact; colour1 to maten!he linl$h of the eng ..... This has a parhcular appllcatloo on motoiIways.

S,...k.I"f1 • s••,ed Joint • Age. heal. press .... and !hIt usa of hard MIt"", Malanl can caUM two component. 10 alicI< le>geIher 10 \9ItIY hi they . . ddfIr;utt 10 ~I• ...-.g linger pr-... aIona. Do no! .......-t to u*ng .............. tn.a ~. P'Y po!IlI providad for tr-4 purpose ( _ ~Iustratlon 7.1) or .... the gasket 'Nil be ~ • UN. so/Haced hammer 1_ lIIuItration 7.21 or a wood block and conventional hammer- to Ilnka l1>li compooatll __ Ilia mat"",.urfaca. ""'lid ~ ~t <;IS! axtf em~I." since th"Y may break 011. II this methOd t.Is. try ~ • wood - - . be!--. the two COIT'ClOOIIIlls.

""'actII

Mosl compcon.nls have on. cor !WCO hollo ... flXaling do ....,. bal ....... Ih. two paa/I.t faca& " . dowel cannot be ramcovl'd. do nOI rlSort 10 gripplnll /I ... ith p/larl - /I ...iII almo.sl c..-ta/nty 0. diSffH1I'd. 'n.'all . clo.a-flttlng $OCk., or Phillips scre ... drlv.r Intco Ih. dco ....1 and lhan IIrfp Ih. oul.r edga of Ih. dowel te> ".. /I.

the _Illig lac" of the components It II Imperat .... that all tree" ara removed tco ansurecorracl sea li ng 01 the new fIIIsket. • Very cerelully ~ tracel of IjIIkIt .way malung sura Ihat tha s.eallng llUtfaces .,. nol gouged or ICO!'8d by the lCfapel' (_ llIullrlllcons 7.3. 7." and 7 .6) Stubborn deposits can be IWIlCMId by IIjJfI'fWIg WIth an -.,il0l fIIIsket rarnC>\lOf. FInal preparatIon col

.a

• Gukets ... used to seal the malmg !Wrlace. b e l _ compot'l8l'1ts arid keep

t.Jbric::enta.1Iukb, VlIQ.UTl or ~ 00I'IIIined wrthm tIM! .....,bIy. Alummium gas~tt .,. sometllne$ found a\ the cylinder joints, but most gaskets are paper-based. II the mating swI.,.. oj the com~\s bMIQ joon..:l ... undamaged the gasket can be Installed dry. although a dab of ......, or VNse will be USlIIU 10 hold ~ ~ pI8ce cUing -ooty • ATV (Room Temperatu .... Vuleanlling) aiIicooe ~ IlUlants cure wIWI e>.pOMd to I'I'lOi$tur. in the alrno$pl'w"a 'fhese...tants ... good at ~lfll'l\l pol. or ~ g&SkeI t..,.., but will lend to be Ior.:.d out 01 the jomt unoer v.y high I~ They ca'l be used 10 rep&.ce • PIlI*" g.sket, but firal make sur. thaI the wk!Ih 01 the poper gUke! Is not _II~ to

the aturrunong 01 Internal components. AN should r>OI be used OIl compooents <::<>ntall1fng petro! (gasof1rlO). • Non-han:llning, ......har<*vog and hard _ong liqud 0Mket com~ can b-. UMd Wllh a gasket or belwaan • mal.I-Io-matal joint Select the &e8lant to sui! the appI;e.tJcn: urW.wuI non-t\arOarlIng seaIalT can ~ used on virlually all joInls; Hmi-harderllng on joint tacH which ara rough or damaged; hard Belling _Iant on JOints WhICh <equ"a • peml.nent bond and era sublICted to high temparatura and pres$Ul'a. Ncola: Ched< fIrsllf ~ paper ~.k.' hili • of sealant

se;NntS

bMd

Removal of old g.sket.nd s,,/ant •

PIpai'

gasket. y,jll most IIkelv come .WWf

complele. lealling only a f_ tr8CeI stuck on

7.5 ••. or • houaahoId acrape<

REF· 1.

Tools and Workshop Tips

the gasI<eI surf_ can be made wrth ~wy fine _bra&iva paper 0( • plastic kitchen scour", 1_ Mkntratlorla 7,S.nd 1.7}

'*'

Old ......' be ~ or peeled of! IXlfI'IPOI*lts, dependong on the type origonIIy

•

used Nota that gaska' lemovaJ compounds .... .v.. I.~ 10 Iv.,;d SCrapIng !he COITIpo!'I.nll elMn; malt. su •• the gasket _ IILOlS the type 01 sealant used.

.....

8.3 ••• and SIP".'I the chain link

S,...klng end Joining

,Inal drl~ ch.'n.

• om. cha",- for

all but small bokes ... cont"",.o'n and do not till.... clip-type

connec:hng hnk. The Cha,n must be broken UIIIlQ • chaon brealw 1001 and the . - cI\airl securely riwll.cI together \ISIfIg • new soft

nv.t-lyptI hnk. eonnec:tmg hnlr.

chain • .-.cal • fIIIW CHing 0YtIr each pon of the Ink and Insert !he link tlYough \he two chain ..,.;" t- MI....tratioro 8..4). Instal. fIIIW Q..v.g

N......

...... •

clip-type

~1186d 01 • nvet-type link. in an emergency_ Val'lol4 chain brwIking .-Id rtYeting looIf; . . . .vaiIabIa, em..

.~cepl

.. MPfIrJI!t looit or ~ .... illustrated ... the accompanyIng photograph. - read the inatructioollllUppIied ""th \he tool careIuI1y Warnlnfl' Th. n.-d to rivet 1"n.w link pin_ correcllY c_nno/ N ovwst",.Md -loss of 00II/"" of th. mo'~yc;" is V1Iry lih/y '0 ......11 It u.. c;hMn " ' - b In use.

A

• FIoIate the chiHro .nd i0oi< for the ..". IiI"Ii<. The oKlfl link pi .... look I,ke they hav. ~

deeply cenu.punched instead of peened ov. like .. the au. pn. ,..... iluslnltion 6.11) and ~~. m.y be. diff.......t eoIoos. PosrtIOl'l the .aft link midway belW-' the $pfOCketl rod ........ the d\ain bn:IaI<.- 1001 _ ant

01 lhe solt

~nk

pons (see illustration 8.1)

Operata !he 100110 push \he pin out through the chaon ( _ M..... tratlon 8.2). On .., o-mg chl,n, ......0 .... !he O-rings (._ IRultl.llon 8.3) carry 0U1 the same procedurto on the O!hef 80ft !10k poll.

Clulion: Cartaln .off link pin • (particularly on the larger chains, mil"

.• ""0.-"'"

.-qui,. th.ir .nth to N Ii," or flnwnd oN '''-)I ~n N pnJSSIId oul using

~

Ch«:k that you have \he correct SIU and Itreng1h 'I'-"d¥d or '-.vy duty) fIIIW .at1 knk the old link. Look for tM Iizto sldeplat. . IIlI$tratIon 8.10) • Posollon \he eIIau\ ends oKl that 1hey ... engaged 0YtIr the ..- sprod<et. On en o.mg - do not _ marking ~

•• ",,"

,...

ov ... the end 01 each pin. loIlowed by th • • ld~a1e (with the chain manufacturer·, marklnglac:lng outwards) ,... IUultr.tlonl 8.5 and 8.8) On an uosaaIed chain. ~ the link through the two chaln 8flds. than In'tell

thtIlldeplat. with Ilia chain manulactur ...•• mar1mg lacing ~ •

Note thaI

~

may not be poeelbIe 10 Ir8taII

the lldeplate using /Ingar pr...ure .~ II ....1"1\1 • joining 1001, assambie ~ oKl thaI the pIatea 01 !he tool cIwnp the Ink and pr.- the aodepIata 0YfIt/ the pills 1_ Mlustnotlon 8. QtlwwOM, use two smaI soc:t..Q pial;«! 0YfIt/

n

Tools and Workshop Tips

REF·'9

Two sockelS p/acIldHCh I!ide 01 tile has8 and held with Slfaight-jawlld self-Iocldng grips (see Hluslration 9,3). d) TNcJ< card IJ8Ch SId& of I;'" ~ held between s traight-jawed seJf·1oc1<mg grips ~)

(S8ft iIIustTlllion 9.4).

8.11 Chain dimens.lons Sil.es commancing with a 4 (89 428) have a pitch of 112 Inch (12.7 mm)

8.8 Assemble the Cheln riveting tool ewer "'"' pin at a time and tighten it fully

Sozes cornmeocing wrth a 5 (89 520) have a Pitch of SIS inch (15_9 mm)

Sizes commencing wilh a 6 leg 630) have a pitch of 3J41nch (19.1 mm) The second and third digits of the chain &tIe relate to \he width of the r'C>Iers, agaln in Imperial unlm, "II lhe 525 shown has 5118 inch (7.94 mm) rol lers (..... illustration 8.11) . •

8.9 Pin end correctly riveted (AI, pin end un""'eted (8) the 'Ivet ends and Iwo pieces oI l he wood t>elween " a-clamp. O~rale the clamp 10 press the s;depiale ov« the pins. • Assemble the joining 1001 over ona p in (follow'ng the ma ker 's Instructions) and tighten I he tool down 10 spread the p in end securel~ (see Illustrations 8.8 and 8.g) . Do the same on the otller pin. Wsmlng: Checll fhst fha pin ends ",. secure snd that tflora Is no dsnger of the sldeplsle coming /oose. If 'he pin ends are cracked 'he IoN linll muSI be renewed.

.&. I

•

.......

Clamping to prevent flow • SmaU-bore fHlKibie hosee can be clamped to prevent fl uid 1I0w whiisl a component Is WOtked on. WhIchever used . ansure Ihal the hose malerial is not perm anently distoned or damaged by the clamp . 1\1 A bfItI«! ~e cill11lP available from IlUIO IICCeSSCl)' shOps (S8ft iIIus/TIl/ion 9, I). b) A w
mtrthod"

------,

Rn.1 drill. ch.in sizing • Chaios are sized USing a 1h"8e d;grt number. lollowed by a suffix 10 denote tha chain type (...... Illustration 8. to) . Chain type .. ";th,,, standard or heavy duty (thicker sodepIatll$j, and also I.01S83Ied or O-ringIX-rIng type. • The first dig,t of the numbel" relates to the p itch of the chain. Ie the distance from the centre of one pin to lhe centre of the next pin (5" illustration 8.111_ Pitch i5 ""pressed In eighths of an inch, as follows:

8.10 Typical chain size and type marlting

9.3 • .. two soc::kets arid a pair of self-locking grips . . .

9.1 Hoses can be clamped with all automotive brake hose clamp •• •

9.2 ... a ";lIgllul type hose clamp • .

9.4 ... or Ihick card and

Freeing end "ttlng ho••• • Always make sure Ihe hose clamp i$ move<:! wel l clear of the hose end. Gnp the hose with your harld end rol ate it whllsl pull ong II off I he un ion. If the hose hll.!l hardened due 10 age and will 001 move. slit rt wil h a ahafp kllife and peel its ends off Ihe unior1 (see Inustratlon 11.5) • Flesist Ihe temptalion 10 use grease Or soap on the unions to aid Installatoon; although il h"ps the hose sl,p over the union II wil l equally aid the escape of nuid from \he )oint. It Is prelerabla to so!t en the hose ends in hot water and wet \he inside $urlace of the hose with water or a fluid which wiH evapornte

AEF·20

Conversion Factors

...... ,-'" .....

length (distance)

.,"

.. 0.305 .. 1.609

• M~(mnI '"' MeIr-..(mj .~(km)

.. 0.0394 '"' .. 3.281 .. 0.621

Volume (capacity) Cubic Inc:toet (CIIIn; In') IrnpeRal plnUo ~mp pi) Imperial quarts {Imp qt} Imperlal quart. {Imp qt) US quarts (US ql) Imptrlalll"llonl (Imp gaj) Imperial ItIlIonI (Imp gal) US gaIor. (US gal)

16.387. CubIc c:.nllmeltw (e:<:; un') 0.568 .I~_(I) 1,137 • ""0 1.201 • us quem (Us qt) 0.946 • Un.,. (I) ~ 4.546 • Ut"'(I) .. \.201 • US gatlonl (US ~ ~ 3.785 . Ut ... (I) .. .. .. .. ..

Mass (weight)

""""" ...... ""''''

.. 28.35 .. 0.454

o..no-Ion» (ozt: oz) POl.OOs-1on» (Ill: II)

.. 0.278 .. 4.448 .. 0.1

Force

_~1Nl

......... .., • ar.rr. (g)

-~(NJ -~(N)

K*lgramI-torc. (kg!; kg)

.. O.OISI .. .. .. .. .. .. ..

176 0.88 0.833 1.057 0.22 0.833 0.2tW

.. 0.D35 .. 2.205

x 3.6 .. 0.225 .. 9.8\

.-

....."

,-'"

Cubic InchM (CII In: In')

I~ pirlUo (Imp plj IrrII*"i*I ql#l' (Imp qt) Imperial quart. (Imp qt) US QUII'lI (US qt) Imperial ItIlIona Omp gal) Imperial ;alIooI (Imp gal) US ga/lOnI (US gal)

""-'''' ...... "" o..nc::.t-Iorw (ozt: oz) f>o:Iundt.~

(Ibf: II)

_1Nl

Pressure

'* Inch '* Pounds-Ion» '* (psi: IbIron'; Ibr'In') Pounds-1Drce '* squwe Inch (psi: 1WIn'; IbIIn')

_..

Pounds-Ion»

$QUIll" Inch

x 0.070 Ki~-~ per $Quare centl......u. (kgftcm': kglcm') .. 0.068 • AtJTlO$i)lle<",{stm)

.. 14.223 ,", Pot.IIlds·1or<:e per $Quare Inch (pII: 1WIn': Ibr'ln') .. 14.696. Pounds·1or<:e per $Qua.. Inch

$QUIII'fIlnch

.. 0.069

.. 14.5

$Q ......

(pIi: IbIIln': I~n')

Poonds-Ioru

(psI: Iblll"': Iblln')

.,

--_.... MiIiber (""*)

Millit.(rnt.) M6bIr{mt.) 1.4.....1... 01 mercury (mmHQ} tnc'- 01 WIll. (lnH:p!

... .

.. 6.695 • KlIopucaIt (kPa} .. 0.01

(psi: 1bI1In': Iblln'l POI.II"oCUo-ioroe per $Quare Inch

11*: IbIIIn'; 1t:r;1n')

'"' Kiognoms-force per _ _

c:.n~ (kQIIc:m'; "",em') • P--.(P~ .. 0.0145 . ~1or<:e1* _ _ 1nch rp.!: 1bIIW; b'In') .. 0.75 • ~ of...wry(rnmHg) .. 0.401 • Inc:I'IM 01 wet. (InI-ylI .. 0.535 • ~ 01 wot.(lnHp) Pounds-Iorce per square Inch .. 0.036 (psi; Ibflln'; Ml')

"CO

.. 0.145

Pounds·~

per IIq\.I8I"e Inch

-._-

11*: tbIIW: IbIIn')

x l1li.1 .. O.Ot

.. 68.8,n •

x 1.333 .. 2.491 .. 1.866 .. 27.66

KiIopucM (kP1IJ

-..., MiIaIr Imt*J

M,1ImetreI of mIfcury (nxnHg)

Inchea 01 WIlt.

QnHzO)

Torque (moment of force)

Poun
.. 1.15.2

Pounds·1orce InchM (Ill"'; Ibln)

.. 0.113

Kilogren-.-Ior<:e <*lIimetm (legl em: kg em) Newlon mttree (Nm)

.. 0.083

Pourlc»-totc. lee! (Ibf n: Illt)

(Ibf in: Ib W1)

Pounc:II . ~

lee! {Ibf ft; Ib ttl

Pounds-Ioroe 1_ (Ibt n: Ib ttl ~meIr .. (Nmj

.. 0.138 .. KiIogramI-Iorcto metres (kgf m: kg m) .. 1.356 .. ~on mttree (Nm) 1/ 0.102 '"' KIIognIrnI-torce metres (kgfm:

.. 0.866 .. 6.85

Pounde-toree Inches (IbI1n; Ibln) Pounds-force Inches (Ill In; Ib WI)

." ""'""'"(lbl'in: lb~

"'"-

,,-'"

Pounds-ton:a feet (Ibt ft; Ib ttl

.0.736 • 9.1104

Pounds-Iorao feet (IbI ft; II ttl Newlon metrM (Nmj

kCiI m)

Power i-IorMpower (hp)

.. 745.7 .. WaItS (W)

.. 0.0013 " H
Velocity (speed) Miles per houf (ml lfIIIhr. mph)

.. 1,609 • Kilometr.. per houf {kmIhr, kpIl). 0.621

Mi_ per hOu, (mlleaihr; mph)

Fuel consumption· MileIper(llllon(mpg)

x 0.35'" •

~per~(krrVI)

.2.625

Mi*,pergab'o(mpg)

Temperature • ("C .. 1.8) .. 32 • h is eor:wnon ptkfIee!O eomwt from

~ F~

o.gr... c.o.. {tlegre. CentIgrade; "CJ • mi/apM~ ~

("F • 32,) .. 0.56 IOlfresIl00domeh$ ~1001rrr\1. ...".,. "¥l9J1I1I00km " 282

Motorcycle Chemicals and Lubricants A number 01 chemicals and lubricants are available lor use in motorcycle maintenance and repair. They include a wide variety 01 products ranging from cleaning solvents and degreasers to lubricants and protective sprays for rubber, plastic and vinyl. • Contact polnt/. park plug cleaner Is a solvent used to clean oily lilm and dirt

from

points, grime from electrical

connectors and oil deposits from spark plugs. It Is oiliree and leaves no residue. It can also be used to remove gum and varniSh from carburettor jets and other

"""*. •

Carburettor c leaner is similar to

contact point/spark plug cleaner but it usually has a stronger solvent and may leave a slight oily reside. It is not recommended for cleaning electrical

components or connections. • Brake llIy.tam c leaner Is used to remove grease or brake fluid from brake system components (where clean surfaces are absolutely necessary and petrol8tJm-basec! solvents cannot be usad): It also leaves no residue.

• Silicone-based lubricants are used to protect rubber parts such as hoses and grommets, and are used as lubricants lor hinges and locks. • Multi-purpoae grease is an all purpose lubricant used wherever grease is more practical than a liquid lubricant such as 011. Some multi-purpose grease is coloured white and specially lormulated to be more resistant to water than ordinary grease. • Gear oil (sometimes called gear lube) is a specially designed oil used In transmissions and final drive units, as well as other areas where high friction, high temperature lubrication is required. It is available In a number 01 viscostties (weights) lor various applications. • Motor 011, 01 course. is the lubricant specially formulated for use in the engine. It normally con tains a wide

vanety 01 additives to prevent COfTOsion and reduce foaming and wear. Motor oil comes In various weights (viscosity ratings) of from 5 to 80. The recommended weight of the oil depends on the seasonal tempel"ature and the demands on the engine. Light oil is used In COld climates and under light load conditions; heavy oil is used in hot climates and where high loads are encountered. Multi-viscosity oils are designed to have characteristics of both light and heavy oils and are available in a number 01 weights from 5W-20 to 2rNo150. • Petrol additivea perform several functions, depending on their chemical makeup. They usually contain solvents that help dissolve gum and varnish that build up on carburettor and Inlet parts. They also serve to break down carbon deposits that form on the inside surlaces of the combustion chambers. Some additives contain upper cylinder lubricants for valves and piston rings. • Brake and cilltch fluid is a specially formulated hydraulic fluid that can Withstand the heat and pressure encountered In brake/clutch systems. Care must be taken that this fluid does not come In contact with pamled surlaces or plastiCS. An opened container should always be resealed to prevent contamination by water or dirt. • CIlain lubrica nts are formulated especially for use on motorcycle final drive chains, A good chain lube should adhere well and have good penetrating qualities to be effective as a lubricant Inside the chain and on the side plates, pins and roll81'S. Most chain lubes are eithM the foaming type or quick drying type and are usually rnarl<.eted as sprays. Taka care to use a lubricant marked as being SUitable for O-ring chains. • Degrease,. lI1e heavy duty solvents used to remove grease and grime that may accumulate on engine and frama components. They can be sprayed or

REF' 21

brushed on and, depending on the type, are rinsed With either water or so/voot.

• Solvents are used alone or In combmation With degreasers 10 clean parts and assemblies during repair and overhaul. The home mechanic should use only solvents that lI1e non-llammable and thaI do not produce irritating fumes. • Gasket sealing compounds may be used in conjunction with gaskets. to Improve their sealing capabilities. or alone, to seal metal-to-metal Joints. Many gasket sealers can Withstand a~treme heat. some are Impervious to petrol and lubricants, while othars ara capable of filling and sealing large cavities. Depending on the intended use, gasket sealers either dry hard ()( stay relatively soft and pliable. They are usually applied by hand. with a brush. or are sprayed on the gasket sealing surfaces. • Thraad locking compound Is an adhesive locking compound that prevents threaded fasteners from loosening because of vitMatlon. It Is available In a variety 01 types for different applications. • Moisture dispersants are usually sprays that can be used to dry out electrical components such ItS the fuse block and wiring connectors. Some types can also be used as treatment for rubber and as a lubricant for hinges. cablas and locks. • Wa~es and polishes are used to help protect painted and plated surlaces from the weather. Different types of paint may require the use of different types of wa~ polish. Some polishes utilise a chemical or abrasive cleaner to help remove the top layer of o~idised (dull) paint on older vehicles. In recen! years. many non-wax polishes (that contain a wide variety of chemicals such as polymers and silicones) have been Introduced. These non-wax polishes are usually easier to apply and last longer than conventiOflal waxes and polishes.

AEF- 22

MOT Test Checks lestar, particularly In vie ..... 0 1 the oqulpmtnl

About the MOT Test In 1!'Ie UK, aU V'ehicles ~ than lIvee ~ old are IUbjecIlo an annual tell to ensure thaI I~

meet nummum salery loqulr_ts. A

t;UfTWI'1\ It$! Qllrtifieale must bot *"-I beIorfI • mactKr>. ca"l be used on public; mad$, .,..;I is required belore a road fund IIc...ce c.n !)II

I..ued.

Flldlng w,thout "

currenl teal

C8!'Ilticala will also Invalidate your Insurance. For most ownt!<$, the MOT It$! Is an annual cause tor anxiety, and thla It largely due \0 own .... not being Iur. wt\tI! needs to be checked pOor \0 SUbmitting I~ motorcycle lor tesllng. The simple .,,1_ Is thaI I fully r<*Iworthy motorcycle woH hs.... no difficulty In paumg !he l8$t

This II a guide to getting your molo
required lor lorna 01 tha checks. How ....... .......:riere. bIIsed on th" rtgUt;ItlOl1'l in lcoree at 1Il10 timfl of pr't1llng. Test tlM<::illrds are becoming Increasingly stringent, atthougn tt-.er. _ some lIXemptiont for older

Certain axceptions apply to machllleS under 50 cc. machines without a lighting system. and CIa$$Ic biI
.-

"a~t"ln

~. More Woonabon about tt. MOT '-I e.n be obtained from the TSO publlcations, How Safe is yQ
In$pIIeIJOtl ,..,.. for ~ Test.lg Many 01 the cheekf; raquire that orot 01 th
......

-.

bordarl.fne condt/on, Iha ,..,... " - diKt'a1ion lit ~

wtoall>8l" top"s 01"

f.n it. " lhe molOl'C')"Cle prnefIlad is

clNn ..w .wdantfy weN cared for, the le.fer' may be _ ;nc/lnad to PIn a

-.

than" Iha Is sc.rurry..w apparentfy

bof'derj/ne compoII8I'It

~

Electrical System ugttts, tum signals, hom and

Headlight beam height

reflector '" With tha IgniHoo on. check the operatH)o 01 tha loIk)wIng electricaJ COf1lPO/l8Ots. Nota: ff/«tri«! componenl$ on certain 31tW1· capecjry m.chInes .,. po.....,.o by the ",","lor, I'IIqlIrilg thaI Iha anginfI is MI frx

n-..

...

-

~ HMdHghf and

b)

rslllighi. ChacJr lhal both //Iumlnale In lha/owand Ngh beam swilCh pOSJlion5. PosJtJon lights. ChacJr that /he Iront posJfJOIl (or sidIIIIgIIt) and t.tiIlighl .JWIte/I posJfJOIl. Tum sfgnIIs. ChacJr thelllll flash at /he ~I nile, and //la/Iha warning Iigh/(s) function contICtIy. Ch«;k that /he tum signal switch worlfs COIfItC//y. Huard waming system (where fflIed). Ch«:k that aR four tum sIgrta/5 /Im;h ., tNt switch poMion. $lop light Check //lat Iha light comn on whM Iha fronl and ' - bta/Ies _ /nd8pendfIfltly~. Models !'irst

arumn.re"lNs

c}

d)

e)

'" The MOT tHt&r will perform a headlight beam height che<;k using spedallsed beam Mltlng equipm~1 (Me Ulustretlon tl . Thit lIqulpment will I'KII ba availabloJ to the Ilorl..mechanIC, but 1/ you suspect thaI the headlight if; Inc:otractty sat or may have bean maladjusted In the past, you C8f1 periorm I rough test as lolows. '" Position the blk' In a straight line lacing a brick wall. The bika must be 011 Its atand. uprighland wiIf1 • rider seated. MeaWlll the height from lhe ground to Ihe centra 01 lhe headlight and mark I horizootallina on the wall at thill heighl. PositIon the motoreycl, 3.8 metres from the wan and draw. vartJcaI

Haadllght baam height checking lIquipment

line up the wall c.ntrai to the cantr.lk>e of the motorcycle. Switch to dipped beam and check thai the beam panero falll allghtly lower than tha horlzontalline and to ItJa lilt! aI the varticallina ( _ inu.trltioo 2).

a.-.r..

UMdon oratler 1st ApnI1986 must h.!ve a blake 11gh/ swl/ch on allCh brnke. f) Hom. Check IIIat the sound Is conf
'" ChteI< that u-. if; a r..:I r.n.ctor

00 thgnallenses.

Home wor1
MOT Test Checks

REF-23

Exhaust System and Final Drive EXMust

", Chl:tCk thaI Ihe exhaust mountings are secure and that the system does not roul any 01 th9 rear suspension components. til Stan the motorcycle. When the revs are Increased. check that the exhaust Is neither holed I'lOf leaking from any of its joints. On a linl<ed system, chock that tho collector box is

.... Note that the exhaust decibel level ("loudness" of the exhaust) is assessed at the discretion of the l(lSter. If the molor<:yclll was 11,.".1 used on or after 1st January 1985 the silencer must carTY the BSAU 193 stamp. or a mar\(ing relatir.g to ~s make and model, or be of OE (original eqWpmeI1t) manufacture. If the

sife
Mm.

Final drive

., On chain or belt drive machines, check Ihat the chain/belt is in good condItion and does not have IIxcessivlI sla<.:k. Also chO:tCk

that the sprocket is securely moonled on Ihe

.esr wh.,.,1 hub. Chock Ihal Ihe cha in/belt guard is In place. 01' On shall drive bikes. check for oilleaklng from the dri\ie unrt and fouling Ille rear lyre.

nolleaklng due to COtrOSion.

Steering and Suspension lock ch<.>ck with lhe IIoIIIight of the machine on the Iowur bearing (see Illustration 3).

Steering

01' Grasp Ihe fork sl iders Qower lOllS) and attempl 10 push and pull on the lorks (see 01' W~h lhe fronl wheel raised off ttle ground. rotale thll 5t_ring Irom lock 10 lock. Thll hand lebar or ,witches must not contact tne fuel tank or be close enough to trap the oo .... s hand Problems can be caused by damaged lock Slops on the lower yoM and frame, ot by the fitting of non·standard handtebar8. 01' When performing the kx;k to lock check. also ensure that lhe steering moves freely without drag or nolclW>ess. Steering movement can be irnpajred by poorly rou!8d cabIea, or by IMIrtloht hood bearings ot worn beatings. The lester will perform a check of the s1~ head bearYIg Io:Jo,yer race by mou:rtlng the front wtleeI on a surface platll, then perlorming II lock to

Illustration 4). Any play in Ihe stooling hood bealings will be filiI. Note Ihat in extreme cases, wllar of the front fork bu!ihIlS can be misinterpreted fot head bearing play. 01' Check Ihat Ihe hand lebars are securely mounted. 01' Ctteck that the handlebar grip rubbers are secure. They should by bonded to the bar lell end and to the thrOl1le cable pulley on the right and.

Front suspension

Front ~I mounted on a surfaca plate lor steering head bearfng lower rt>Ce check

Checking the steering head bearings for freeplay

tI' Wilh the motorcycle off the stand , hold tM front brake on and pump the front forks up and down (see Illustration 5). Check Ihal they are adequately damped.

Hold the front brake on and pump the front forlts up and down to check operation

REF-24

MOT Test Checks

Bounce the , .... , 01 the motorcy<:le to check rear suspension operation

InspeCt the ani. &found the fork dust sea' for all leakage (arrow)

mod"''

Iog)_ On SO equipped, cheCI< that t'-" is no oil leaking from the antl-dive units tI' On models with swingafrTl Iront

sus.penSlOl1. check that thefe is flO fre&play in the linkage when moved from side to s;de.

Rear suspension

check that th ..... is no !.>gn of oil leakage /rom Its damp.... This Is somewhat 'flStricted on certain s ingle shock models dua to the

k>cation 01 the shock absorber. tI' With Ihe rear wheel raIsed off Ihe ground, grasp the w~ at the highest point and attempt to pu ll it up ,see Illustration 8). Any play m the swlngarm PIvot or suspension linkaga bea,ings will be fell as movement Nole: Do nOI confuse play with IlCfUilI sllspensiOll mov,,,rnml. Failure to lUbricate

Cl>ecking for rear suspension linkage play '" Inspect the area above and around the front Ion. 011 nals (see iIIustrat!on 6). There should be no sign 01 011 on Ihe lork lube (stanchion) nor leaking down the slider (lower

'" Wilh!he molorcycle of! the stand and an assistant supporting the motorcy<:la by its handlebars. bounce the rear suspeoaioo (see must.atlon 7). Check that the su spension components do not foul On any of the cycle parts and check Ihat the shock absorber(s} provide adequate damping. "" Vi_lty I~t !h8 shock absorbarjs) and

Worn suspension linkage pivots (afTows) are usually the play in the rear suspension

cause 01

suspension 110k8\111 bearings can lead to bearing tailure (see Illustration 9) tI' With the rear wheel raised off the ground,

grasp the sw inge,", ends and attempt to move Ihe swlngarm from sidtl 10 sldtl and forwards and backwards· any play IocIlcalas wear of Ihtl swingarm pivol bearlngs (stle illustration 10).

Grasp the Iwlngarm at the ends to check 101" play In tis plvol bearings

MOT Test Checks

Bnlka pad we ... can u"".1Iy be YIewed without removing the cel• . Most ~ have _Indicator groove. (1) and soma a llJO "'va Indicator t.lIn~ (2)

REF· 2S

On drum ~k_, chel;k the M>g~ 01 the openting IeYer with the brah fully applied. Most drum brakes have a WflI. indicator poInt. . .nd $elI1e.

Brakes, Wheels and Tyres

......

-....

top to bottcm. Have .., auistanl hold the brIII<.e on 80 thai the IIuid In tht hoee Is under pressure. and check that there Ia 00 sign 01 fl uid le.kaga, bulge$ or c,.elclnll If

' - frQm

0/ With,tIe wheel rliNd of! 11M groond. WY the brttke ~ off, and checII ttwn the wMei III about \0 revoIviIlTMIy witIIout

then""

". On disc brakes, uamln. the disc

Cheek that

~

'"

sec~r.1y

~sel1.

moonied and nOI

cracklld.

.... On disc brakes. via .... the pad material through the caliper n'IOIJIh and check that the !*IS _ not worn clown beyond the limit t_ llustfatlon 11) '" On drum brak.. , check that when the brake Is applied the angle between tile

_•.

operallng leve<" and cabl. or rod is not too

greal {s. . illustration 12). Cheek also thai

tha Operating laver doesn't loul lIfly olher

'" On diK brak. .,

.~.mI.,.

the IIe)(ible

there a•• any matal brake pipes or unlOfl8, check ttwn ~ •• fr .... from ClOfTOIIon and damage. WIleR • brake-linked aml-dlv •

system is fittlld. cIMock the " ' - to the antidive in."",,,,,,,,,,. '" Check that tha rear brake IDfque ..m Is ae<:unt and thaI it, laSlaMB are ae<:ured by self-locking nutl ()( castellated nuts w~h splil_ pn or R-pi ... ( _ Ilustration 13). '" On models with ASS. check that Ills MIIc:I'Ied< warnIng tight In the instru."..,u pansI

-.

'" The MOT t.... wi. perlorm a lest 01 the motorcycle'. braking efficieru::y baMd on • ca lculatIon 01 rldar and motorcycle walght. AIthoogh IlIiI caMOl be ca
air"

_1pedaI1eeI (bleed 01 Iu epongy) and pad material. For drum brakes. check adjultmant. cable or rod operation and shoe lining thick.-.

....... ""'.,... '" Check the wh&91 condition. Ca.t wheejs should be free from cracks and H of the builtup d ..lgn, all la91_1 shooJld be secure. Spoked whNll shooJld be checked lor ~ corroded. loose or bent spokea. '" With Ills wheel raised 011 the ground. spot> !he wt,..; and visually check that the tyJe and wheej run t..... Check that the lyre does nol

1ou11tle sullPlJll*lOn Of

m~dl.

'" With tha wh",,1 raised Off tha ground. grasp the wheel and attempt to tI'II)Ya it about the axJa (SpIndle) ( _ IIluatratlon 14). Any

play felt t..lndlCates wheel ~ taIk.n.

AEF. 26

MOT Test Checks

'" 11 the tyrfI sid_ali carnes. dirflClIc)n 01 rotatIon arrow, tl'lll mu,t be pointing in the

direction QI nO«l1,1 whtoel rotation I... IIIu8trlltion 16). til Cl>eck that the whNI axla (spIndle) null

{where applicable, .r. properly !<$Cured. A. MII..Jo<.:UIg nut or cultolll..cI nut wilt! a spit.

'*'

C.,t.JllIt«I ~ whHIllJlle (spindle) nut

Two atnolghtl
mutt be HCurltd by 8 split pin or R-pln

whMI a llllnment

.

........ ,

'" Chec::k the lyre tread depth, tread condition and aldewall <;Ond,lion {'"

types must be compatible and be ..... itabIe for road use. lyre. marked NOT FOR ROAD

., Ch«:k U. tyre type. front and

USE. COMPETITION USE ONLY wlllalltM MOT.

feW t)ft

Of

"mUar,

General checks and condition " Chtoek ItM MCUrity of all major fut......... bodypo....., ....1, fairings (where lilted) and

.......-

II' Check that the rider and pIiioo lool ... t., tIandIebIIr ...... and brIOke pedal 111'8 MCtQIy

~" .

or R-pin..., be UMd (see U.... lnltion 17), '" WhHI a11Qntr1en1 • clleck«l with the motorcycle of! the stand and • rtder seated. With the front wheel poIoIlng IU'8igh1 ahMd, two perlec1!y straogtrt IengthI 01 metal or wood and ~ ~ 1hoI1Idewa"" of both ~ lsee Illustration 18). The gap each side of the front !yr. must be IIQukHst8l1! on both ,idea. lrocorrecl wheel alignment may be dlHl to II cocked . _ wheel loft., as \he r-..II of poor

-

ct... adjustrTMnt) or ~ unm. C8IS8S, II bwII

'" Check for corrotIon on the frame or any "-i~ componentS. " _ _. this may .tfect the strud...., ~ under SIreM.

Sidecars A motorcycle I~ ted with II alci8car requ.lrea addlUonal chltCks relallng 10 Ihe slabll~y at the rnechirIt UId MeUrity at allachmenl and

swivel Jolntl. ph.... peciflc wheel allgnm&nl (Ioe-In) rtqulremenll. Addillonally. Iy'. and IigtTtIog reQIJifemenI' differ /rom ~tlor*

motol"!;:ydo U$I:I. Own
Storage

REF-2'

Preparing for storage ....-nove lhe 1PIIr\( plugs and fit them bacI\ In

Before you st art 111W1j)a1r100.n~II...-1ed._thoa'

IhiIIII c.m.IIO !Ide 1t>e bh ~ ~ It. bike • good ~ .-Id scrub .. dIr1 /rom lIS und«sicle. Malee SUfi the bike d ..... completely be1.". ~ IQt storage.

Engine • Fternov. the spn plug(1) Md Ltric:III' IhIo ~

botw whh appI'OXlmaIeIy

IhW ~ ......... thai !he pIugI .,. ..u..d (grourIc*t) agMwt the eyIRier "-i...m.n !he ltar1er is OJ*lIIMl (-. Illustration 3) Wam.!ng: It III ./rnpc:IIUn1 1M' ,he phJgs __h«J (grout>d«ll ~ Iwq from _ pNg /loin oth_1H ,,,... II • f1slt. o f .,~ tu.I from the ~ /gnIfirIg.

At...

-'*

!f the bike II going ,",,0 Iong·twm storage, ~ -'ding • fuel ~ to the fuel in the tank. II In. tank is dr.,ned completely. corroeIon of n. lnIemai surfIoca may OOCU" W lelt unprotected fOI' • long petIod. The Iani< can be "Htee! with • "'II ~",,"tlv. especially lor thl. purpose. A"amatlvely. ~ the tank and po\lt hall • .w. of motor oil Into II. In,'111 the filler cap and lllake tile tank 10 COllI It. Inl ...... '- wl,h oil before

•

<:hining off the peep.

I \.-poon

Crank the ""gina ov.... (;oupl. 01 Ii ..... to 00II1 the piston rings and botes wi1h oil. HIlle

•

bike has a IOCkstart. llH this to tum \tie engine over. If not, flick tile kill • ....,tch to lhe OFF ~tlon and crank the -.gIIM ov.. on I hto It8rMr (aM IIIustnItJon 2). " the f'I8tIn on tne ignition system ~ the ItaIt.- ~ wIIh the kill swllch In the OFF po,mon,

n.. _

.t/ec:1 .,.,

also be ach....-.:! by spraying Wa.O or a eImiIar _er-dl1J*SlM wound the ir-'de of !hII tank viii Ita IIexIbIoI nozzle.

01 motor oil USing 11Ij)OUI·typ. oil ".., ( _ Illuat.. UOfl 1). Re!n8111i She aparI< pIugIl)

•

0nwl!he~1)~u.....1s.

risk 01 /
Squirt • drop of motor oIIlI"Ito - " eyIInder

••• !WId - . thet 11M megl bodiH of the plug, (afro...) .,.. urthed ag.lnst the cylinder IIHd

Flick

M .... ~ the cooling system ~!he

cor,&<;t mil. of anttf,aezo. Antll,ooz_ al ... contaJ .... imporIant COfTOSion inhibitOfl. • The_~IOIId ___ ""'~..-Iao:I 011 by covtorIng or plugging lIMo openings.

Ensu.. tlMot you do not MIll In any cond .....UQn; run the 1II"Ig, .... un!. Ills hot.

thoo klU ,witch to O FF ••.

Connect , hoM to 11M c~ I\oaI chamber drIIn , tub (I"OWj and unac .. w thoo drain ac .. w

REF'2.

Storage

• C~ the aleetrolyta level and top up If necnaary (conv.nli<)nal refillable batteries). C'-" !ht' lenninala. • Siora th' battery off the motorcycle and away from any ilOu".:es 01 fir... Position a wooden bIoek under lIle battery il ~ is to sit on

lhe ground. • GNe the batlery • trickle charge for • ,_ houri evety month , _ iIIustnltlon 7).

Tyres • Place 1M bike on Its centresland or an

UN • .uIt8bIe '-HIllY c:n.ger • thi$ kit -.0 ...... blotter)' oondition

then IlWIICh of! and a/Iow to cool. Tape a piece of IhK:k plastic 0_ th' silencer end(s) ( _

a.. llilary Iland which will support It>e motorcycle In an upright position. Position wood bIocka uoder the tytes to keep !him orr the ground end to provide insulation from damp. If the bike is being puI into Iong-Iwm storage, Ideally both tyres should be oft the ground; nol only wWI this protect the tyres. but wIU IIlso 8OSUI1I thai no load is placed on the steering head or wheel bearings. • DaHlia each tyre by 5 to 10 psi. 00 more or the beada may unseal from Ihe rim. making

01 cold the bIItt.-y may

-.

case 1_ M..... tratIon 151.

•

ill"s tratlon 5) . Nota that some ad~ocale pg~'ing • lablt$pOOll 01 motor all Inlo tile $ilen(:erj.) belen _ling them off.

Battery • RernoY.

~

from !hot bikt - in _ . - 1rM>:. and <;m<;k its

lubHquenl Innatlon dillieul! on lubelesl

Pivots and controls Lubricat. all 1eYet. pedal. stand and

1001,.t plvOI poInta. If grease nipples a... lill~ 10 the rear suspension component • • apply 1u~1 to the pivots. • Lubr\Cllte 1111 conlrol cabIfI8.

Cycle components • Apply. W8)l protectant to all painted and pIIIstic componenta. Wipe off IIn)IUc.s. btrl don't polish to.~. WIlenI fined. clew! Ihe ~ with ~ and waler. • CollI ....... p..-tS with Vaseline (petroleum )eIyI. When ~ \his to the fortIlIbM. do not compran the fOfks Oth«wlH the ..... wII rot from contact WIth the v....... • Apply a virIyI cleaner to the _I.

Storage conditions • Aim to store the bike In a shed Of garag.e which does not leak and Is free from damp. • Drape an old blMkel or bedspread ov ... the bike 10 protect It from dust and direct conlsct with sunllghl (which wIll lade pelnt) This 111110 hides the bike from ptyIng .y.. Bewa,e 01 hghHiltlng plastic covers which may .-ow condensallon to form and setu. on !he bike.

Getting back on the road Engine and transmission • Ch.ange tile 011 and replace the oit filler. this was dooe prior to storege. check tllat the 011 hasn" emut'lfled - • thick wh ltiah substance which occur. through condensalkln. • Remove tile ap&n\ plug., Using a spouttype 01 can. squirt • few drope of 011 into the cytlnder(s), ThIs wII provide initial IubricaIIQl'l as the piston IIng8 and bores ~ back Into contact. s.vtce tI>e ~ plugs. Of fit new ~ and tnst.I tt..... in Ihe engine,

• Check Illel the clutch isn·t stUCk on. The plates can .,lck together ~ left standing 10f $O~ time. p,.venllng clutch op&ratlon, Engage I Q$ar and Ify rockil'lQ the bi ke back and lorth with tilt clutch lower held against tlla handl ebar, II thi s doesn't work on cableoperated cMchM, hold tlla clutch lever back agaln't tilt handlebar wilh a strong elastic ~ Of e.bIe U. lor • couple of hours (SH

I"u.tmion 8l. • If Ihe air Inlakes or slIencer end{s) were bIockad ott. rernow the bung Of COYer UNd. • If tile fuel lank was coated wflh • rust

Hold ckttch ....... block -.gains! the handlebar with eI&stic banct. Of a cable tie

prevenl8lw., oM or. atablli_.x;ed \0 the fuel. Or.. .,0 Ikoah the tank and dispose 01 IhllIueI .....bfy. II no action .... taken with !hi fuel ..... PI'\Or 10 1IOfa!il8. II is advised Ihat the old fuel is dIIpoMd 01 WOOl It wiI go 0/1 _ I pa10d of tkne. RefII the fuel lank with

....,""'.

Frame and running gear •

Oil all pivot poInUl and eaDlell.

• Cneek th' Iyr. pressures. They will definitely need 1011111"9 It pressures ""_ reduced IOf atorage.

-,. •

LubOca'a the flRIII driY1l chain (wiler.

• Remove any prot«:ttve coating applied to

the /00( ~ (atancNonll..-.ce tIW rTI8'f wei destroy the fork _... II the fOflr. tl,lbea _ ... '\ protected and MYCI pic:ked up rusl Spotl, remova them with vwy line abrasiwl ~ and ..trilh with mobil polish. • Check that bott1 b!akes Operate COfTeCIly. Apply each bfaka hard and check that ~'. not possible to mova the mototl'y<:la forwards, then check II'I~I the ~ fr_ off again once reI6ased. Btakto callI*" pistons can Slick due to corroaklo around the plslon head, or on \tie slkling caliper types, dUI to corrosion of the

slider pins. II the brake doesn't Iree aft .. repeated operation, tak, the caliper oft for ~Ion. SimI'-!y drum brak_ can stick

--.

due 10 • HIl;ed operating cam, ....,. or rod

• II the mol~ has bHn In Iong-Ierm !he brakIo IIuid and dutch IIuid aloooge, _

...... ,,0<*1.

• 0e!Jend1llQ ~

and

on where the bike kas bMn the wIrIog. ~ and ~ INI'f t.v. nibbled by rodents. Make a visuII check

~t~.

diatUl'blld wiring loom t~.

Battery • II the better)' has DeerI Pf9\'bJSIY fOI1'lOYal ."d given lop up charQ8S It can simply bto .-.connected. Remember IQ CQfItleet t'poosItIVe C8bIe IIrat and h negallve cable last. • On conventional refillabloo banllriM. II h balliif}' r.u not reeeIved any allIlllUon, ffItl""O;)\/e IlIrom h lTlOIorcyockI and cNclo; lis electrolyle lave!. Top up if ntICeSSIIIY tllen chiIrga the betI-V. lithe baII-V faD to hold e cn.ge and e ..... chec;ks show '-"Y wtota sylphatlon of the plales, the battery It probably dtllICIIva and must be.-.-.d. ll* II partN:Ylarty likely If 11>1 blttety I, old. Conllrm blltety condition with I specilic gravity checl<. • On Malad (MF) banerles. if the batt..-y hils not rtcaIv..::! any Inlll1lloo. remove II from the motOtcyc~ and ch8f911 II aCCOfd11lll to tl>l inIormIItion on tile betlwy case - if the benery lalla 10 hold a charge II must bI!I renewed.

Storage

REF' 29

Starting procedure If a ldckltart is ftTted. II.m Ihe angor>t _ a couple 01 limes Wllh the 19nItion OFF to diIIIb.ota 01 .uund h ~. If no kickstarI It fitt..::!, ftld< the.-g"'" k* ,witch OFF and the IgruIIon ON and crank the engine _ a ~ oj _ 10 wOOc 0I1r01.nd h upper cylinder COII'IporMInts. If tl>l nalur. 01 11>1 IgrVtloo lV-111m is suc:tl thaI the start.. won't work with the kill switch OFF, remove tha span.. plugs. flt !hem back Into tnelr c;apI and earth {groond) their bodies on the cyllndlf head. ReQtaIl the span.. plugs alt_arda • Switch the kiI switch to RUN. operata !he ~and starttheengine. If the er9ne won't UMI don~ cornInlIe c:ranIc.ulIlIOtS CIIIl bkx;k jefI • It a CIItIuraI"Ior cJaa_ doesn'l prove successful Ilia CIltlUr"8rtor.t mtlSl be di:smll1t/f1d lor eSean/ng.

•

• Onee the .... gine haa sl arted. check thai the IIghttc, Il.m"IIIgnals and hom wOOc property.

• Trut the billa gently lor tile firlt riOt and check all fluid IeYeIs on completion. Settle the bike t.:k Into the mIIin-.ce scIleduIII.

AEF'30

Fault Finding

ThIs s.etlon proYidoM ... easy r&ference-guicle to tht ~ COITmOn faults that ar. r.kfly to afftlC1 your mach,ne. Obvloutl~. the opportunltlM .... almost Ilm,tless lor lau~ . 10 OCCur U • result 01 obIian ,...... and to try and cover aI w.ltualitlea would r.quIte • book. IndNd, • .-...nt:. ....... ~ written on tht aobject. ~ful ~Ilng is nol I mptar\ol4 '1)Iaek .,-t' but tht application 01 • bII 01 kno~ combined wilt. • IlySIMJlIIIC IIO'Id Iogic:aI approKIIlO the problem. Approach WI)' troubIe.nooIing by I'nt 1ICCUI1It8ly identifying \he symptom and then checI<.ing IhrougtI It» Ii&!

1 ene'''' doean't stert 01' I. dlttlcutt to .tart Start.. motor dONn" rotate Startlll' motor rQlat .. but engine doe not tum ov« Stlll'l. wotks but «ogIne woo'' tum OY« (MlZed)

N."...... ......

,.".. No S!*l< or week eparIt

"""""""" _do ...

--_.". ." i -~

of possible c.u.... Ilarting wIth the almplest or most obvious end ~ In at.o- 10 !he most compIelI. Take nothong lor grant..:!. but at:M:w..n apply tibe
7 Abnotm4tl eng/". no/•• Knockng or pinking Pi$ton """" or .. tiling Valve noIsa

"""'S AbnonrMI

2 Poor ruM/no ., low speed

TranarniSSiOn l'IOII8

Filial dnve nolle

9 AbnomMI frrune Mtd suapenslon no/..

"""'-Frontend .....

"""""""" ...

Fuel/air mlot.... ~

Brake ooO$fI

Poor ~1erat1Ol'l

3 Pool' running or no power .t high speed ''''''air mixture Incorrect Compression bw

""""""'~­

•

-~

o;:::-'-'!.

FueI/..- mod ..... ~

~tootllgh

EngIne load uCW6lYe

l.ubrIcIItion

~1JaI.

MI..::.M""OUS~u_

5 Clutch problems

'0 0.

Clutch shPPlng Clutch not dI~ completely

, ~/1IfI problems DoeoIn"go intO~. or Iever.x-n'j retum .IurnpI out 01 ~

.I:l ICI

ID "-""'"

driIIfIl/ne nol..

""""-

&*afI.~

10011 p,... .u,..low

0; Engifle IlbrIeation ayttem

"""'....... ...... "" g...........

11 Excessive .xlNlust smok.

12 Poor IuIndllng or .tltbIlity

:0: Hardabars IIIIrd to tum

:0: Handlebars llhaka or vibrate ~ o Handlebars puN to onto IIIda Q

Poor shock absortling quabto81

13 Braking probI.m.

a

..... ...,

Brakes are spongy, don't noId Brake laver or padIj pulset.

..,-

14 Electrical problem•

....

Banery ~ or --"

Fault Finding

REF- 31

1 Engine doesn't start or is difficult to start Starter motor doesn't rotate

o o o o

fr9ne ktI PIitCh OFF. t=u. bkJwn. Check ...... fuse ~ 9). s.n.y von.gt low. Check and ~ t.rt,.-, p.pt.. 9). ~ motor (IeIectIve. Make SI.n It. wiring to !tie Nfl. II M(;lA. ~. ture Ihe start« '*f c;kka """'" !he Nfl button Is puIhed.1f the.....,cId<s. then IhetUt II in Ihe wiring or motor.

D St.1$".-.y~. Checkit3lX:Ofding to !he JlIOC*IIn" Chapler9. St~ ... .wi\ctl1'lQl coo\.llCttng. The contact. could bIo wet,

o D

o o

o

corroded or dirty. DisassMIbIe arid clean the awitct1 ~er 9). Wiring open or shorted. Check all \Wing connec:!lOOI and ~ to make au'" thai \hey are dry. tight and 001 corroded Alto check lor broken or frayed wires thai '*' ca.- • ahort to NrtI'I (ground) (aM wmg diagram, Ckaptw 9). 9"ffiOn (mIIln) $WIIch deI«:tIve. Check the Iwlte/'I .ccon:IIng to the prOCedIn In ChapI.. 9. Replace the switch with • MW OM If ~ ..

-.

or

EngN kII swlteh defectiwo. Check lor wet. <*ty corroded or ~ \he switcn as r - v p.pc- 9). FIUIty stIrt_ CUI.oft relay, diodes,~,"'" st...:I ordutct\ rMtdI. Check IhII wiring to --" switd1 and !he switd11tM1f IICCOfding 10 the PfOC*b'eS in QIaptar \I

conIaCta. ~

Se.rte, motor rot.t •• but engine does not 'urn over

o o

Starter moIor cIuIch

defflCtive. Inspect and ~Of_

(Chapl.2).

lei""

Olll'l'\&ged or .tart... gears. III$pftCI and parts (CI\IIpt..- 2).

renew the damaged

o

Seized tngine caosa:I by one or I1'lCIfe ;'t.nal!y ~ componentS. F..... due 10 _ , ~ or ~ 04 IubricIItlon. ~'*' ~ sCed \/8IWIS,~. CM1IhIIIts. pislonI, cra"IkahaIt. ~ rod be9Mg5. Of I~ gMra 01 ~. ReI. to CNpter 2 lor ....... ~

No fuel noliit'

oo o o

o o

tw._

No tu.l1n tri. Fuel Wok hoM obstructed. Fuell\II.c:towed. CIew1 or r....w fill. (Chap!« 4). FlltII tap vacuum hoM apIiI or detached (750 !l1I)(\tII;). Check the

-.

Futl tap dlaphre;gm

spI~

(750 rroocIeIs). R _ _ the tllP and check

the d~plwagm (Cllapter ~) f ..... ~ ..... cIo\IQed. Pull the luelline kx>H and catefully blow

""""'" ..

D Ao.t ............. c:ioQged. Fa- .. 01 the ........ to be c:ic:Wed, IIithaO' I ~

_

*'-.,.

'-I belch 01""" wIIh an ......... eddidYe t.a ~ 1MId, or oIhar foreign mIIteriIIIhB.nta'ed 1M lank. MWry I

mectint t.a ~ stored leo" ITWfIIIIlCII"Ih wIIhouC "'""*'II, IMIueI tun-. tol --....e1Quid and tcrrr. ~ on Ihe IMI .....

a.

Engine flooded D float height too high. Check _ deeabed ... c:hIIp'- ~ o float ~ ........ worn or stuck open. ,.. piece 01 cIrt. rust or oIhar debrie can ClIO.$I the ........ to MlIIImpropoIrty. cauIIf1g ~ !!AI to be admitted to Ihe no.! c:Nmber. In this C8$8, Ihe no.! cI\arnbIr should be cleaned and the needle velve and s.eod inepected. If the needle end _ I are worn, thIrIlhe IeIIkiog wiI J** ..0 tIM perU. should be ~ with new ~ (Chapler a). D Starting tac:hniqo.lt 1ncorTeCt. Under nonnaI ClfC\lffi8taooea (Ie, H all the cart>ureltor funelions are eound) the mac/WIoI should star1 with little or no throttle. When the tngine • cold. the .;hoke IhouId be operated and the ..-.gIne lUIf1ed without opetq the ttvottIf. When tIw ..-.gIne • II oper1Itlng lempWlture, only a ~ slight amount 01 ItnIttIe should be~. If the.ngine isllooded, tool the lUll UIp OFF or ~ theY8CUUll1 hoae ~ to modIiI-_ ChapC. a) and hold the ItnIttIe open while aarN-og the ....... lhos .... &low IdcitionIIIIir to ..-:h the ~. RenwnbIf to tool the fuel UIp t.ck ON or .nac:h the .....::u..m 11<:*.

No sparle or weak sparlc D

o

o o

o

Starter wor... but engine won't tum over (seized)

o

va/vee and)tls.. "The~"" IhouId be rem:MKI and 0\IeIt-..Ied W
o

ignition IlWitch OFf. ignition circuit fuM blown. Engine 1<111 .wrtct> lumed to the OFf position. Battery voltage kIw ChecI< and rechlll{l8 the battlll)' I I necesasry (ChapterS). Spark pIuga dirty. defective 0< worn 0lIl. Locate reason for fouled plugs using apark plug condition chart and follow the plug main~ proc«II.nI (ChapI'" 1). Sport plug cape 0< aeeondarY (HT1 wmg f~. Check condillon. Awwweitherorbothcomponenlllifcrad<sorcletericntionare

-~. D Sperl< plug ~ not making good contact. Make .... thet the

plug cape lit .,.qy OY'II" the plug endI.. ignition contn:IIlnt ~. Check the Int (ChIpIer 51. Pick-up cot delectlve. Check the ..-.It (Chaptw 51. Igoition HT coIiII deliIICtMo. Check tIw cois (ChIpt« 5). D Igoition 0< kill switch Moned. This is usually caused by WIlIer, corrosion. damage or .~ceasIve _ . The swrt~ can be disassembled and oItened with eieclri<;BI contact cleaner. II cl6aning cIoaa not htlp . . . . - the switcl>eS (Chapl'" 9). D Wiring lhorIed or brOkan beI_: ~ 19n1rion (main) switch end anQIna IdII switch (or blown /gtIh1on fusa) b) /gnIfIorI control unil and '"""" IdII switch c) Ignition c:or>irOI unit wrd IgnIfIorI ~ ooiI::s d) Igtlltion ~ coOII MId JP&rl< p/U{p e) Igtlltion control urJI MId pick..." ceil D MaN SI.ft thai .. wImg o;:onnact;on5 are dean, dry ...,;I tlght. Look for ...,;I broQn wItea (a.>t
o o

o

ella*'

REF·32

Fault Finding

1 Engine doesn't start or is difficult to start (continued) Compression low

o o

o D

o

Reinstall arn:llight.,., to the s.peclfied torque (Chapter II Cylinder head not s.uffk:iently tightened down. If the cyhnder htoad Is suspected of being loose. then there's a chance that the gasket or head Is damaged ~ the problem has pwslsloo for IIny length of lime. The head nuts should be lightened to !tie proper torque In the correct sequence (Chap!"" 2). Improper valve clearance. This means that the val .... Is oot dosing completely and compression prllSl:lure is ~ng past the valve. C/ltICk and adjl.lSl the valve clearances (Chapter tl, Cyj lnder and/or piston worn. Excessive wear will caliSe compression press......, to leak past the rings. This is usually accompanied by worn rings as well. A. top-end ovemaul is necessary (Chapter 2\. Piston rings worn, wook, broken, or sticking. Broken or sticking piston rings usually Indicate a lubrication or carburatloo problem Ihal causes excess carbon depo$ns or sei>:ures to form on thfl pistons and rings. Top·eod overhaul is necessary (Chapte.. 2). Piston rlng-tC>-{jrOOVf! clearance excessive. This Is caused by

8Kcessive wea. ollt\e piston ring lands. Piston replacemeol is

o

neoossary (Chapter 2). Cylinder head gasket damaged. II !he head Os alklwed to become

loose, or if excessive carbon build-up on lhe plslon crown8l'ld

o o o

(omproper C81"buraltOn) or an accumulallon of carbon depos~s on the seat (from earbl.ration or Il>bricatlon problems). The ~a1ves must be cleaned and/or renewed and the seals serviced ~ possible (Chaplet" 2).

Spa>1\ ~ug81oose. Remove the plugs and inspect their tlYeads.

combustion chamber causee extremely high compression, the head gasket may Ieal<. Retorqulng the heed is flOt always suffident to restore the seal, so gasket renewal is I'lfICe!ISIIr"y (Chept.... 2). Cylirlder head warped. This Is caused by o~emootjng or Improperty tighteooo head nuts. Machine shop resurfacing or head renewal Is JleC8SSa/)' (Chapter 2). Valve spring brok9n or weak. Caused by componenl failure or wear, the springs must be renewed (Chapter 2). Valve not seating property. This Is caused by a benl ~aMl (from ovet"-rewing or improper ~aIve adju51ITmflI), burned valve or seal

Stalls after starting Improper chol<.e action. Make sure the choke linkage shalt IS Q9ttlng a full strol<e and Slaying In the out position (Chapt .... 4). ignition maHunction (Chapler 5) carourettor malfunction (Chaplet" 4). Fu~ contaminated. The fuej can be contaminated with ",,!her dirt or water, or Clll'l change chemicalfy II lhe machIne Is allowed to sit

for several months 01" more. Drain the tank and float chambefs (Chap!er 4). Intake air leak. CheclI for loose carbl.lrettor-to-Intake manltotd eonnections.ioo&EI or miSSIng vacuum gallge adapter screws 01" hose plugs, or loose C81"bure\!or tops (Chapter 4). EngIne idi9 ~ Incorrect. Tum Idle adjusting SCrew until the eogjne Idles al the sp&Cifled rpm (Chapter I)

Rough Idle

o

ignition maHuncllon (Chapt .... 5).

Idle spe«llr.com:d (Chapler 1). IncorT8ct lIif/fuei mixture setting (Chapter 4) Carboreit(l<S not synchronised. Adjust carburettors with vacuum lIa..ge or manomater set as described In Chapter I. Carourettor malfunction (Chapter 4). FIiIII contaminated. The fuej can be contamlnatoo with eltherdut or water. or can change ctlemoc:ally H the machir>e Is allowed 10 sit for several months or more. Dram the tanl< arid float chamber.! (Chapt .... 4). Intaka a" leak Check tor loose carourettor-to-Intake man~oId connactions, loose or mISsing ~acuum gauge adapter screws or hose p\1.>g5, or loose carburettor lops (Chapt .... 4) Air Mer clogged. Renew the air fi~er elemant (Chapter 1).

Fault Finding

REF- 33

2 Poor running at low speeds ~powanlO .... ~theo'onga.n..~ axoo,.,.1i&d by wom nnga ....... A ~-'*'IiI ' - Y (Chapter 2). Plstoo ringI worn, WMk, btoMn. or SlICking IItoI
Spark_ak Ballery voltage low Chect: .,..;I ~ ~ery (OlIpW 9j gp.I< plugllouIMI. ~«worn 0lIl. ReIer to ChIripter I lor

IIJ*II pIug~. SpIrt< 1*'\1 cap or HT ......->g ~_ ~ 10 ChIpt_ 1 and 5 lor ~ on the 9VtIOfl.tem. $perk plug ~ not mII
Pistonri0'"9-~~~-

c:ot'01""

_ . Of If .....-..vOI .." •• Ixlo'

(

or.-paw dell1C1lVt1 pens F.......... too hogtI or too law. ChecIt t~ level (Chapter 4)

clIunPf, and _

F..... tarlk btwoilt .

~

ot..ltueIlICI

c.t>u-.tto;w w,1ak.- ",...../oIdIIIooH, ChecI< for....,.... breaks. t.-. or 100M dim!». ~ the Intake maOIfoid joints it opIitorpw.twd

"""'*

<;:tOWn""

(Chap'-2).

Poor acceleratIon ~or.lNkinOordirty,o.whauI_~~ 4).

Compression low Sperk plugllooM. ~ the pIugt WId Npec! tt.. '"-:b ReonstaH and Dgh'-> to the.-.roed IOfqUe p.,p.;. 1) ~ ' - ' not ..1!IcienIIy tight-*, down. II the ey\IndoIr " - I

!here",.

p t - . e IIIMking pM;t IhIo val . .

0-=1< and IdjuII the ...... ~ (CtIapIer 1)

eyns. rdlar posIOn worn. ~ _

...... <*1M

TOO'W"OII not~. The pick-upQOil Of th81gn11ion CO'IIJOi /TICJdlje may be defective. If 10, !hey ",... be repIeced wnh . ..--.. as !hey ten', be ~. cart:ueflor. not~. AdtUII ~ wrItIa VKUIM'n ~ $It (CIIapt. II EngIne 001 VIICOIIty too high. UIIng I hMYi8f 01 tt.... IhII , .......... , . odoo:I in ChIptar I ten dImIIge !he 01 pump Of UIrIc:a\Ion syslem n _ _ chg on 1I'II.-.groe. Brakes cngg..g. lISI.I.ay e.uI8d by debRI wtIo(:h hili ent.-.d !he tnke piston ...... Of Ircm I wwped dISC or benllIde Aepao" .. ' - Y fChapter 7) Fuel pump IIow rate Wl$UIIlaenI. ChecI<. _ pump (ChIpI. ' 1

or"""""""

.. .uspKted 01 being 1ooH. then ~that the o-keI .rid " - ' . . ~ ~ the ~ 11M ~ for any length oIlme. The ' - I no.n.lhouId ~ IIQht«Ied 10 the Il'OI* IOfqUe In the CCIIf.:t ~ ('Chapter 2). 1rTIpr'OJ* ....... ~, Tl* ~ that the ....... kt not cIosmg ~..,.;I ~

budd-up oolht piIIoIOO

co:OOus\lon chlwnber ' * - exl...w/y hIgto ~, !he ~ ~III may leak. RetorQ\q!he ~. 001 ~ aufficieol 10 _ I..... _ MBI, 10 gaeke1 . - - • neceuary (ChapI .. 2). Cylinder hMd wwped. Thi1; • caused by ~bng Of IlTlpfoper\y hgh lened hMd nutl, MaclWlt .r.op r...nactng Of hMd I"9fIe'WlII .. ......::essary (Ch~I" 2). Valve spOng broken Of weak. caused by compOn8r1l lailure Of weer, !he ~ must be ~ (Chapt.. 2) Valve 1101 sealing propet!)', Thia t. caused by a bent valve (from o_.revvIng or IlTlpfgpllr valve .cIlus""-'lJ, burned v..... Of _ I ~mprOP8f carburat>on) Of en lOOCumulallOfl 01 carbon depOIiIs on the ....1 (from cerbOJraHOO, lubncabon ~. The ......... must be clsarl8d and/or _ « I and till _IS MfVUd II pc!SSIbIe

Fuel/sir mixture incorrect P'Aot ~ OUI 01 adjustment (Ch.apl• • ) Pilot jet or ... passage dogoed. I'Iemowo Ind 0YfIfhauI the catb.nltora (Chlop1. 4) ,... bleed holes dogg«I, Remove carbure110r Ind blow out all passages teMpter 4) An Mer clogged. poorly _'-d or""'*'1lQ (Chapter 1) AA fi~. tlousIog poorIy.-.ed. Look for cracka,llojee or ~

n...-....cI by

.. ~ _ cr/ the poSIon mg ....... Pilton-.lll nacessay (ChapIer 2) CyIoodw hNId gIISk • .s.rn.ged. II the 1....:1. ~ 10 become

puahed on to the pIugII Ir'IoclncI aper1t pIlogs. wrong typt, hM1 ratIge Of cap oont\go.otiotI- a.ck ..wi InStall COOIiC1 plugS lINed in c::t.pter 1. \gnIbon un
,

AEF- 34

Fault Finding

3 Poor running or no power at high speed eJ
Firing Incorrect -0 IW lIIter~. CI&an Of ~ n~. (ChapIer 1). s,p.k plugs 1ouItod, ~ Otf worn out. 8M Chapler IIof sp8I'k plug !TICIint..-oo.. Spark plug capt or HT wiring (lef.ctlv •. See Chapt_ 1 and S for details 01 the 19n~1oo Systllffi,

g

o

Spark plug eapt 001 in good contac:I (Chapter 5). IncotrecI spail pIuga. Wrong type. heat r&nQII or c.p QOnfigo.nllon. CI-.ck Md nstaI correct plugs IIsIed In ChIpIer 1 Ignitian control uM def...w. ~. S). Ign!tlon coils del«:tlve (Chap* 5).

D Fuel/aIr mixture Incorrect

o o

Main jet clogged. DIrt, water Oil ot/"4r conl8mirwlls can dog the mIin jets. CINn the fuel t.p filler, the ....... tllter, the fIoaI chImber .e&, .nd the jets wid c.rburettor artIIoM !(:haptBr .). Main jet wrong Iiu. The standard)e!tlng Is lor _ ...... atmospheric prwauII ~ carblntlOfS

o

"""""'".

o o

-=

over-<eYYk"lg or~"""'~. btmed v.... or_

possible (eMptor 2).

Knocking or pinking c.bon build-up In combuaIIon c:I\wnber. UN of • fuel .sditiYI tIwI1 ..... ~ the..:ltw.iW bonding the c.bon P"~ to ~ crown and chamt- Is the . . . . , W1rf to ....-nove !he buiId-up. 0!he<wIH. ~ cylinder head wHl ha .... 10 be removed and

defectlva part..

cartuettor intake ",...,.otX ~. Chec:k for aaeI<s. broeks, t. . . Of 100-. ~ Replace !he ntlber Intake ~ IIIhty we spIiI or petWIed (Chaptlll'

4'.

Compression low

o o o

o o

o o

Spark plugs ~. ReIr>oYto the pIugIaod Inspect their thread&.

-m...-..

d!ocarbonIMd

~Chapt.- 2).

IncarecI or poor quality /uti. Old or ~ gndM of /uti c.-. ca..e _Ion. nu. ca.. !hi piston ,., rattle. thus the knocking or ~ MlU"Id. DrlW1I*l/utlWod .tways use the

Rw-QI Indlillh*' tolhe ~ torque ~ I), cylinder hHd noI IUfIiciIIntIy tigI'rI..--d down. " h cyInder hHd II -...pectebMm tIwd caaM _ _ c.bon ~ or 1IO!IizufM,., form on the pislOnS and rings. Top-eod ove1\euI It roeoe8MIY (Chlipl. 2). pj,ton mg-I~ clearance ex~. Th~" c.l.lHd by

CyIin$r ' - t wwped. ThII. It ca.-::I by ~ 01 improperly IighI.-..d " - I nuts. M.a-1Iho9 ~ 01 " - I .-.-aI It neces&ar)' (Cheplor 2). Valve IPMg broken or weak. Caused by component lailu.. or ~ IPfIncp mvat be ...-.ed (Cheptor 2). Valve not.-llng properly. ThII.. ceused by. bent va/w (from

(impoper c.rbIntionI or en ~ of c.bon depoeits on the _ (from CIrtxnIion or lubrication ~). The v...... must be c'->ed NIdIor ............:I aod the _IS ~ If

o :==';:,i=.~~~k>ose repa;, Q ~:::: ~= ~~":' the ....... (CIIapte< 4),

II the ~ It ~,., become too:.e, or If ~ cartoon buIId-up on the ~on crown Itld combustion etwnt-..-.- ex\relTlely high oornpression. the head gasket may leak. Ro»orquIf'l{l the head It no! always &utficMln1 ,., .-.store the MIll, to gasket .-.-III II. neceaery

o

(ChIpter 4).

clamps, and replace or

of the PlSlon mg lands. "-'on ...-.. It

~ (Chapter 2). CyIin$r ~ gaket~.

D

'....... '''.doid /uti gradIi.

Spark plug t..t range irIcotTKt. Ur.::ontron.d detonation 1ndIcat.. the plug heIIl ~ II. too hOt. The plug In I'ffect bec:omM • plow plug, ~ c-,iInder 1ImpenI1.........tatt the proper ' - t . . . . plug (QIIpIor 1). IrI"iIlItlI* wnuel tnixtur&. ThII. wII c... the ~ ,., !\.WI hot. which .... 10 _0011. ~ jets or en ........ c.-. c.uM 1mtIIlInce. See Chaptor •.

11'1.

Miscellaneous causes D Throttkt ....... ac-o·t open f\.JIIy. Adjust the trwottle grip IrMpily D

o o D

o

"""'" "

Clutch lipping. May be CIUMd by Ie-. 01 worn dulch compor$"Ih.. Relorto ChIopIor 2 for clutch overhaul procedurM. Torrklg

not"""ancing

EngiiW oil viK:o&Ity 100 hogl"l. UIIng a tIM,,*" oR than the one ffiICOJI'WlWlde In Chapt... 1 ean dImage !hi oil puonp or LobricItion S)"IIIIm Ind CIUM dr.g on the ~ &akM dragging. l.JsuIIIy CIUMd by ~ which .... ..-.ta-ed the IlfIke piston . . . . or !rom • w.-pId c;t;.e or bII"II axle. F\epItr . .

--

Fuel pomp !low ralelnlufflctent. Ch«:Ir.!hI pump (Chapt&r 4).

Fault Finding

REF· 35

4 Overheating Engine

o o o

overheat.

Compression too high

CooIanl level low. Check and add coolant (Chapter 1). l.eIIk In cooling Iystem. Check cooling system IlOHS and radiator lor IIIIIka and ott. damage. Repair or renew I*U as .--.ary (Chapter 3). Thermosta! sticking open or dosed. Check and IWIeW as deM:tbd In cnapt. 3.

Fautty radiator eap. RIIrl'Io¥t rt. c;ap.,.;l ' - ~ pre$5InIl.-ed. Coolant ~~. Hev. tne..-rt..., syalem dnuned and ftUlht
o D

Engine load excessive

D

Clutch $lipping. Can btl cau30IId by cIamaged, ~ or worn ckrtcII WllopOi .... '1s. ~ to cn.pt., 2 lor ov.t'IauI~. ,.., EngIne oIlloMII too high. The add~ion 01 too much oil wi caIH p<'UUI1sation 01 the crankcase and inefficient tngine opemtion. Check SpecHications and drain to proper IeYeI (_ Dally (pre.fide)

-> EngI .... oil v\soo$ity too hogi'!. UsIng • he;,lvief oil than the one

Firing Incorrect

....

Spark plugs f.::.Md, dfllflCtlv. or worn out. see Chap!", 1 tor s.park

-~ plogs.

o

Inc;ornt(;t ~

Igrutoon cootrol UM delec110ie (Chaptar 5). Faulty IgnitIoo HT coils (Ctlapler 5).

Fuel/sir mixture incorrect

o

o u

o

reeomonended Wi Chapter 1 can damage the oil pump or lubrication syslem as wei .. cauM dnoog on !he ~. BnIkes draggIog. UsueIIy caused by debris which has ..rtwed !he brake piston aeUs, or from a warped disc or berot axle. Repair as

-..,.

Lubrication inlldequat.

Main jet clogged. DIrt, wat. and olhtor c:onteminants can clog !he maln )ets. Clean the fuel fi lt .... llllIlIoel cOilmbir 1""" and the juts and ~or ~ (CnapIw .), M;WI Jet wrong ail .. The lllaodatd )eltWlg Is lor _

Carbon build-up fn comooSI>on chamber. Use of a fuel addit,Ye tNll wWI dissolve the adl'Mlva bonding !he carbon partlcI.- to the piston crown and ~ Is !he ~ way 10 r8I'IlOYe !he buik!up. Otherwise, !he cy\indtlr head wiI have 10 btl ......-ed and decarbonised (Chapter 2). Irnproptrty mae/'Iined I...-d su1_ or nstaIIatoon ot ~ ~ ~ .-.g'ne lISMfTIbIy.

lwei

atmospheric prftSIX8 and oxygen content. Air 1iH. clogged, poorly MaIed or missing (Cllapler 1). k Nt.- hot.-.g pocwIy -'ed. Look tor cracka. holes or Ioc.e cIampII and ~ or~. Fuel level too low. Cheek the k!veI (Chap\6I" 4), Fuel '-nk breather t.os. obetructed.

c.tluArttor InlakalTlllflifolda 100M. Check lor ctaeks. breaks, tears Of 100M damps. ReMw the n..obber ~ manfoId joonts if split or pf.IrishecI. 11lClOmIC\ pilot ICfew settlng (see Chapter 4).

Eng, .... oil level too low. Friebon caUNd by Witerminent lad< 01 Iubo\cetion or lrom oil lhat I, overworked can e&US8 oveoheioting. 1M 01 ~ a definite cooling Iooction in ItMo engone. ChedI the 01 level (CMpter 1). D Poor qualfty qlne 011 or Incorrect viscosity or type. Oil is rated not onty acCO"ding to Yiacoslty but al$<) lCCQtd,ng to type. Some D

oil _

not rated high enough for ~ in tIW ~ 1_ o.Ily

cheeI<sl. Miscellaneous causes fpte-~)

Mod/IICaIion 10 iIlIhaust system. Most aIteomar\(et exIwIuat systtms cauM 1tMo...gone to run ........, whietI ...... 1htm run hott... When lnatanlng lin KCeSSOIY 'xNlIIt aystem, .rways Mel< ~ on rejettlng the e&ot:ourenOl"l.

REF'36

Fault Finding

5 Clutch problems Clutch .1Ipp1"fl Ffiction ~_ worn or ~. Overhaul the cII.ttch -m::oIy

o o

o o

""-

..

Plain ~ ~ (Chapter 2). Clutch aprlnot broken or weak. Ok! or l\6at·darnaged (from sjlppiog duteh) ~ $hould be replaced with..- or(Chapler 2). Clutch centre or housing ~ty worn, ThIs ca_ ~ ~I of the plat... Renew the damaged or worn pwtI

"""""' ..

Clutch not dl_ngltfllng completely o Nt In IIycQ.JIc ....... 1IYS*n. BIaed the syst... (_ ~. 2). CkM:h pIIIt •• w.J*I or~. This wiI - . . . clutch chg. which In tum wiI C8Ia. the ITIIIChine to creep. ev.m.uIlIw (i.rlch

o o

essemtlIy ~ 2).

CkI\c:h IPring len8ion . . - .

u-av CIOUMd by • MQged or

6 Gearchanging problems Doesn't QO Into filler or lewr doesn't ,.tum

o o o o o o o

see

CIutc:h not di~. 1Ibowt. Selector 1oriI(I.) bent or seized. ceuMd by dropping the ITIKhIfIe; or from Ia:k oIlubricatJon o-tIauI thIo tr~

on..,

~.2).

Gear(s) ,1l.IcI< on wit. MO$I oIIen caused by llac:k of lubricatioo or 8!eamg:s and ~. 0vemauI the !.anemls!llon (Chapter 2). ~ector drum binding. Caused by lubrlcalion hI~ ur. or .~cesslv. wear. ~ the drum alld bearing (Chapter 2}. Gewchange leY.- reto,.m epOOg weak or broken (Chapter 2). ~!eYer broken. SplInes stripped out of lever or shill!. caused by allowing the !eYer to get looN or from dropping thIo 1TIKhine. ~ ~ partS (Chapt. 2). ~ mecIIaro$'T1ltopper am broken or worn. Fill ~ 8Ild rotary movement of seIecIor drum ...... ~lhewm~2).

o

Stopper am ~ broken. ~ am to IIoaI. calU'Ig spcncIie shifI. op.ralion. ~ sp1ng (Chapter 2).

Jumps out of u ••r

o o o

Selector fun«s) worn. o-t.uI !hot \I1Insmission (Chaplw 2). Gear grooye(s) worn. ~ the tnonsmIssion (Cl\apter 2). Gear dO(IS or dog slots worn or damagoId. The QO!W'I ahouid be Inspected and renewed. No att .... pc should be made to..vlce

the worn fW1s. Overse/ects

o

Stopper arm spring _ _ or broken (Chapter 2).

D Gean;haoge ah.tl retLWn -.:ring pas! broken 00' disklrled (ChIpI... 2j.

Fault Finding

REF.37

7 Abnormal engine noise Knocking or pinking Carbon I,lI,IIid-Up., combustion chamber. UN of al\lel additive that wiI diHolve the . . - . . . b<:lr1df'Ig the carbof1 partlcIea to the poston <;"""'" and charntl« is the ~ wrt to .....aYe the buIdup. 0tharwiM. the cyIincIw head wi. kII .... 10 be removed and ~

co-.-

2). Incooect or poor quar~y fuel. Old or imPfOl*' fuel can cause deIonatJon.. ThI:I ~ the platoos to raW., ~ the knOcking or pinking sound. DraIn the old fuel and haY' liSe the i6Wii .... id6d grMle fuel (Chapter 4) 1J Spark plug heill rw>ge 1ncomK:t. Uncontn:oIed detonation ncticIt_ thai the plug heal range Is too hot. The plug In eflecl becomes a glow plug. r-'"'g C)1kIder lemperalurM. Qt.1111he proper hMt range plug (Chapt.. 1). Ifl'IPrOPIIr _/fuel "'I)m.... ThI:I will C8O,de the cyIi~ to NO hoi and lead to detonabon. Clogged jets or an IIIrIeak can c:.JSe ~ Imbalance. Seo Chapter4,

o

Piston slap or ra ttling

o o

o

"",,",-

.

Pi$lon seizure damage. Usually from IfICI< o! lubflcation or oYMtIoNling. Aebore !he cyI""'* bIDet< and fh ' - plstona (Chapter 2).

upper or 10_ end clearaoce a~cesaive. Caused or *II at lubrication. AepIace worn I*tS wI1h

Valve no/..

o o o

IrIOOfTOct YaM! clearances. Adjust the c~ by ,~etrIng \0 a..pterl , Valve spring broken or weak. Cheek and renew v..... ~ as a aeI (Chapter 2).

Gan'tsNoIt or c;:yInder head worn or damaged. I...:k oIlubfIcallon 81 high rpm is UStJaIy \he caliSe 01 damage. InsuffICient oil or I"'" 10 ~ the 01 at the '&COiI". oded intervala . . the chilli C3iJSeS. Sine
Othernolu

o

CyIjoder-lo-piston cleanince ."ces8IYe. ~ by ~ --ooty.1nIpOICt and ~ top-end I*lS (CIIaptor 2). Connecting rod bent. Cau!Mld by OYef-rewlng. trying to!Marl. badly flooded engine or from ~ • ~n oo;.ct Into !hoi oombusllQl1 chamber. ReMw the damaged 1*\1 (Chapter 21. Piston pin or piston pin bore worn or Mi:zed from _ or 1...::10. 01 Ubricatlon. ~ ~ l*b(Chapler 2). Piston ringlaj worn, broken or ' tlCl
--.

ConnectIng rod by IIJIC8Uiw _

Cylinder head gaaket RkIng. Edlaust pipe leaking at cyIirIOItr ~ ~. CauMd by Improper iii 01 pipe(a) ~ 100M exhaust flange. All eldlaust fa&~ WICUd be tlgllteoed eveoty and carefull')'. Failure to do this wII '-d to a leak. CraJlkshaI!. runout II~. ClIUlild by a bent aaokahal!. (from _-<eYYIngJ 01 dam8ge from . , upper eyIinder wmponent failure. aIao be attribuI.:I to dropping the machine 00 .ntw of

c...

o o

the crankatiaft ends.. Engine rnoo.wrtlog boha Ioou. ToghlWl l1li ~ fTICIU"lt boha (Chapter 2). CrwoksheI!. ~ worn ~ 2). C.... chain 0If t~ asaembly delectr.o.. R..-- according to the ptOCedlAln Chapter 2.

8 Abnormal driveline noise Clutch noise

u

o

CIut~1I nou.IngIfricUon plate cIMr..".,. excealve (Chapter 2). ,..., I.toaM 0If ~ dutch ~ pam. and/or boha (Chapter 2).

Tr"nsmisslon noise

o

[i

BeIrings worn. AIle inct.Ides the poAIbMy \hat the shalts . . worn. Overhaul tile tranamiMioo (Cl'Iepter 2). Geara worn 0If chipped lCtIapter 2). Melal chf?a jammed in geer teeth. Probably poeces from • broken clutch, geer 0If selector mechenl8m that wwe pIck.:l up by the ~. Thia wit CIUIe eerty beaiIng I8Ibe (Chapter 2).

EngIne 011 level 100 low. ea..- a howl from tranamisslon. Also effects erog.ne power find dutch operation {Chapcer Il.

Final drive nol.e

o o C o o

ChaIn no! edjuOIt.:l property (CIIapterl). Front or __ sprocIIelloose. TigIltWl fas~ (Chapter 6). ~..-.d~worn.,,*-_."'~6).

Rear spnX:ket warped , Renew sprockom and chain lit. ""'(Chapter 8). LOOM 0If worn ...... wtlIMiI 0If $pfOCkM COI.I!)Iing ~. cn.ck and _ as r - * l (C/utpter 7).

REF· 38

Fault Finding

9 Abnormal frame and suspension noise Front e nd noise

o

o o

o o o o

o

Low IUd level or Improper 'o'iscosity 01 ., fottIs. ThiI e.n .oI.nd like ~ .-ld • UIUlOIy ........ , ipiIi lied by m.gue.1or1c action

(Chap!.6). Spring weakorbroken. M....... ckkngorw.plng -.:ound. Fort; 01, ..mtn ~. will have • 101 of metal pa
o

Brake noise

o

o o o

n.

Shod< will be c::ov.ed with 01. ReMw shock or SMk MMce on repair from. YfIrMhIo dMIer (Chapter 6).

DehIetiYe ahock ~ with irrternaI damage. lJIoI illn the body 01 the ahock and CM" be remedied. The shock m ....t be repIae«I with. new one (~6}.

new one

Loose or worn IUIpWltIon linkage COO .....J ..iWits. Chec:I<. and..-as ~ (ChapI. 6).

Shock absorber noise

o FlJId...,.. 1ncorTeet. Indicat_ a leak CIIlJSed by ~ MIl.

Bent or datnagMI ahock body. ~ the shock with. (ChapIer 6).

o o

Squeal caused by ptod ..., not InstaDed or positioned correctly (where fitted) (CIWrpt. 7). Squeal cauud by dial on Ink. pads, U$I.lIlIIy IOIXId In combination with glazed pads. Clean using brake cleaning ao/vtnt (Chapter 7). Contamination 01 brake pads. Oil, brake nui(l or din causfng brake 10 chatter or ,.queal. Clean or renew pads (Chapter 7). Pads gbulld. Caueed by .~cessIve heat from proionged ~ or from contamu...tion. 00 not use sandpaper, tIITIIIO"Y cIolh, carborundum cloth or any other abrasive to ~ the pad s.urfaoes as ~ 'NIl stay in the pad material and ~ the

elisc. A. vwy fine IIa1 fila (3l be 1IS8d, but pad renewal ill suggested as. CIA~. . 7). Oi&c warped. Can C8UM • chatllrIng. cidung or Intarmltltnl squeaI. 1..IaaIy ................ iIIId by . pulsating kwer and uo-. tnIOOg. ~ !he dlK(t) (Chapt. 7). Loose or worn wheel bMrings. Cha(:t.; and reoww _ fI88d«j (Chapl.

n.

Fault Finding

10 Oil pressure low Engine lubrication system '1 Engine oil ~ low. Inapecllor leak or ott- problem uuelng low oil ...... lind Idd ,~011 (Chap!. 1). EngIM oil ~,oo low. Very old. thin 011 Of an Improper wtoIght 01 011 uMd in It.-~. Change to COfTKt oil (ChIpI.. '), EngIne oil pump ~. bIo<:kad oiIltrainef Q'lUZI Of fahd 11IIief".,.... CatTy 00.01 oil ~ checklCMP*" I).

11 Excessive exhaust smoke Whit. smoke

e o

f>!S1On oil ring worn. The ring may be brOken Of ~, eaosoog oiIlfom the crenkcasa to btl pulled past the piston Into the oomboIItioo chamber. RepIacfIIha rirlgs wi!n ' - QI'MII (CtIaIlI. 2). Cytloo.te worn, c.ac~ed, or!lCOr9d. Caused by ovemea1ing Of oil starvation. Che<;k !he cy4inder block. lubrication system and cooling lV-I ..... (aM Chapters 2 and 3). VIIM! oil .... damlIgo!d Of worn. RepIIooe oil . . . . with ~ QI'MII

"~." .... gukIe worn. P.tomla ~ valve jab (ChlrpIer 2). ...... EngIne 011 ...... too high, wt'kh caus- the 011 to be Iorced ~ the r'onga. 0rJ0n 011 \0 the proper IoMII (ChtpI8f 1). H.-I ~ brokWI ~ oil return...:l cyh:Ier. 01110 be poJIed into the combuBtIon ~ ~ the lINd gaekeI lind ~ the hud for ~ (ChapW 2). A.bnormIII ~ po:eaIIisaloon. which rorc. 01 pW IIw ...-00-. Clogged breelller • usually the c:a.ae.

c.-

Black smoke D Air millf c:towtd. CIeiln or....-- tho! element (Chapl. 1).

o

AEF·39

Gams/l;llt or joumeJe worn. ExOlOSliMlwear causing drof> In oil pres!lUffI. RepI&Ce

cam Indlor/c.mshatt case. AbnormlIlwear

coukl be o;aused by oil starvation at high rpm from low 011 Willfll or improper weight Of type 01 oil (ChaPt. I), CrankshafI....,;I/or bearInga worn. Same problems as abcMI. Ched< and renew cr.nkIhaft .nd/OI ~ (Chapter 2).

D

o o

MaIn ,iM too \IIrge or~. CompIn!hol jeI aiz. to the SpeciIIcaIlonl \CNI:>I_ .). Choke cabIfI Of linkage nil stUCk, causing luel to be pulled

o

ttvough choke cieuII (ChaPter 4). Fu&lIevtIIIOO hogh . ClleCk and adjust the noal helght!_) ..

o

necessary (Chapl..- 4). Float nMdle v...... held of! needle uat. Cl8arl tile I\oIIt chemberS and fuel line and ...-- the needles and uats ~ . - - y {ChapMr4).

Brown smoke

o

9

Man ;.t too IfIIlII or~. L..-"I condibon -.-I by-ong size ....... jet or by • _tricted orifice. ca-. float ~ and jeI$ and ~ jet ..... to ~ (ChapI_ 4). FulllIIow NuI!IcIInt -lloet .-Ila ........ atucI< ac-d due to cIlemk;ooI .-:tIon w\1tI old fuel; fuelloMII inI;lOnKt; _tncIed fuel .....; faulty fuel pump (Chapt. 4) . Carblnrtor Intaka ~ o;Iamps "-e (Chapt.- 4). Ail: Iil.- pooo:tv M$Ied

or noIlnstaied {Chept_l).

REF. 40

Fault Finding

12 Poor handling or stability Handleba(s hard to tum

o o

Steering head bearing adjuster nut 100 t~h1. Check adjustml!f1\ as

o

described In Chapt_ 1 . Bearings damaged. F10ughness ClIO be fejl as the bars are turned fI'om slde-to-slde. RepId...e bearings aod rae.
n

dropping the machl..... R~ damaged parts. Oon't try to straighten the sle«ing stem (Chapter 6). front tyre air preuura 100 low (Chapter 1).

Handlebars shake or vibrate excessively Tyre5 wom or out 01 baIaoce (ChiJpter 7). S......ogann bearings worn. Replace worn b8ar1ngs (ctlapter 6). Wheel rim(s) warped or dal'l'lllg6d. Inspec1 Wheels tor nor'lOUt (Chapter

n-

O

o C

D

bearings worn. WOf1lront or rear wtleeI bearings can cause poor tracldng. Worn front beatings -Mil cause wobble (Chapter 7). Handlebar clamp bolts loose (Chapter 6). Wheej

ForII yoke bolls loose Tlghten them to the specified torque (Chapter 6). Engine mounting bolts loose. WiI cauae lIXceui'o'e vibration with iocr8ilsed «lgl!'le rpm (Chapter 2).

Handlebars pull to one sIde

o

Frame bent. Definitely IWspecllhls if the machIne hIlS been dropped. Mayor may not be accompanied b'i CtaCking I'\ear the

benet Renew the frame (Chapter 6).

"Wheels out 01 alignment. Caused b'i ilT\PrOl* location 01 axle

D

spet8fS Of !rom bent Slewing stem or frame (Chapter 6). Swingarm bent Of Miete
r.

rmptId daimage. ~ the ann (Chapter 6). St_ng stem bent Caused b)' Impact ~ Of b'i dropping the

motorcycle. RerMw the lteering stem {Chapter 6).

D Fro tube bent Disassemble thl! fOOcs and renew the damaged D

parts (Chapter 6). Fork oil level uneven. Check and add or drain as necessary

(Chapter 6).

Poor shock absorbing qualities D Too hard· ~ Fot/c oiIleYlllucessn. (Chapter 6}. b} Fot/c oil vix:o$Ify too high. Use alight.,. oil (s.- the SpecifIcations in Chapter 6}. c} Fot/c tube bent. Cau$8S a /Iatsh, sticking feeling (Chapter 6}. d) Fork 1nfern8/ d"lTI4fl8 (ChBpter 6). a) Shock s/l8f/ Of bodY benl or damaged (ChllptfN" 6).

f) g}

Shock intemal damage. Tynt pi8SSUffI too high (ChatJI$t" I}.

D Too soft: ~

b) c)

d) •)

Fot/c or shodI oiIlnsuflfcient IIIIdlorlealdtlg /ChIpter6}. Forie oiIltweI too .tow (Chapter 6). Forie oil viscosity too light (ChBptfJr 6). Forie sptlngs weak or brokf'JfI (Ch8p1$t" 6). Shock Internal "-mega or ~ (C/IIlpt$t" 6).

"'T1

III

c

REF.42

Fault Finding Equipment

Checklng engine compression

.... ,tc;h (eng ..... atop .... ,Ich) to OFF and h.m IhIIlgf'Htoon ~ ON: open !he IIYonIe f\IIIy and Clank the engine .,.... on !he start. moWr

lor a =upl, of ..... oIuhons unl,1 th' ;aug.! theltar!er w'il1'IQ( O!*'ta with the kiI-'Ich OfF, tum the ignition ......tdl OFF and ,..,. to Ihe '*"- paragraflI'I reeding stablliM5. ~

• Low comprenlon WID , . ."III in exn-uSl 1fT>Oke, I..-.y 011 ClORMIITIPbOn. poor atartmg and poor poIrlormanee A c:omprelll.lCfl tea' wIll p!'O'o'kM; usefut onlonrolllOll about 'n ......... COIlOJIOOfl and ~ perlormed~, can give w.nlllg or t~. bet""' any otllllr symptom. l>M:ome .~t • Ito compr~n gtluo- wHi be rllqulr&d, 8Ioog WIth .. adapt .... to IWII lIMo spark plug tIY.-l SIZe. NoI
5 lnalen tile spark plugs bad! Into !heIr RJppressor caps and arrange the plug MlcU'OOes . , that their met<>l bod...... ..u..d (grouncltd) JIQ$II'IS! thII eylorder r..:t; th .. i......entifll to p...... nt to tile I"nltlon system es the et\Qln. Is spun O"II!"

dama".

'SM Illustration 21

10_ tl'oen t.pfICIt.ed. Inspecioon 01 the topend ~ will tie reqo.oQd 8 Low oorn~ pIWSSUI'I may tie due to wom cylinder tlorII. prstons or rIngt. flll1uno 01 the cylinder held (j3&k8t. worn v........ or poor wNe _\lng. II To dlStlnguoah betwe«o cyllndllflpiston _ and VIIIve . . . . . pour ..... queototy 01 01 Into tile bore 10 lempOtanly Mal the paton n~. \hen "'I""'t the comprNsoon \ellIS lsee IIluatratlon 3) If the Ihow

"*-'

Position the plugs well

"'*'

u..n

• notlc •• tII. Increase In pr..,ur. this confirms th" Iha <::yllnd..- bor •• pliion. or rings worn. If. how........ Chlngoo is Indicated, the cylinder "-* gasket ot ....... should be uemined. 10 Hi"h compreuion pr.....un Indlcat.. SlICMS/Ve carbon build-up In the oornbusllon ~ and on the piston crown. If this is the

.r.

.-y from lIMo pIuI/ holes otherwise tIl8I'e ... .oak 01 atom,Md fuel escapln" I.om the combustIon chamber8 and ignltln" .... a ..rely precaution. CO\'IIf the top of the "al.,.

co_ with rag. Now tum the IgnitIon ,w,te/! ON end killrWIICh ON. open the IIYoItIi ,...,. • nd c.ank the engIne ov« on the ltertll!" motor for • coupI. of .lWOIutJomo

unt~

Atlll!" one or two revolutIons the p ......... IIhouId bulk! up 10 • maximum f'lllJl1l and t~

{I

"etllhw. Tak. a

cas. tha cyhllder head should be removed .nd th. d.poslts removed, NOI. thai alIC*ISI.,. carboo budd-up Is leu bkely wllh the .-:I on rnodmIlUeis .

the

~ ~ ItabiIMa.

Screw the comprnalon Qlt\IQtI tdapler Into IlMo ~r1I plI,Og 1>0.., then ac:rew the II"UIJtI Into the lldapl ...

Cl'Ieck.ng battery open-circuit voltage

not. 01 this readlr.g and on

mult>-cyIinder qloes repeat the t..t on the 3 On klckstart-equ,pped motorq1:les.....k.

an the ignition SWItdl • OFF. U- open \he IhronlIo filly and lOck the ~ .,.... " couple 01 ~ ooti the !jIIUge

'-*"!iI1IIa"*-

. On~_~.wtonly,thII

d"'_

wi. lIepotndong on the natln 01 Ih' Ignition systlKTl. Flock tile engi"e kill

proo;;edt.q

~~

7

2

no. correct ~ _lJYIIflln CI'IftI)I"

lithe ...... Jts fall WIthin thoo tpICIfIed rIfV' and on rnuItH:y\nMIr engonII -'I are reialove/y eq"';, the eng ..... II In good condItIon. II th .... Is a ma~ed dilf ...ence between th. readlr.gs. or if tile readln". 81. ~I>onI,

no

A

w.....~The~~by

,

Iha t.tfllf)' ..... pPIoeJoIa • " -

•

smok. or ~ WI)' . , . " . . In Iha vicinity 01 fha t."..". N.vw

allow fha IMctrI:oo'YtlIIo C'OiJr.ct yDut' skin or cIotlllng - It If don, WIsh It 0"- Ind . . . Im~te m«Ikli Ittenl/oll.

Fault Finding Equipment

• Bekn any eIectrIcaIlaun is lnvestlQattd ho t.tt.y .,.., be checked. • Vou'l~.dc~cr"""""to

~ '*'erv voItllO'l. Ched< ,"-' In. '-:b .... Ins&rted In the correct moats on the _ . red I8ad to~'" black lead 10 ~.tlv.

'I.. (.".). (_va), Incorrect connections een

damagoI the meter. • A IOUIId 1uI1~-ctlarged 12 volt ban..., Mould prcocIu<» ~ 12.3 ....:112.8 vaIt$ tICfOM ~. term,,... (12.8 volts lot •

1'l'llWtlMance-1rM bIItl")1. On

~

with

.8 volt batt...,. vott.o- IhouId be bel_ e.l....:18.3o;o11s. 1 Set I molllmeter 10 tha 0 to 20 volll de

to n.t In the

REF' 43

INctrolyla's ""'Ihy compwed with !NIl 01 wat .... Water ha. an SO 01 1.000 and fullych wglKl battery ....::trofyte ;. abOul 2e" heavier. at 1.260. • SpeciI\c: gravity cI\e(:b are not poaIbIe on maInt____ frM batteries. T.mg the 01*'elrcuit vol~ '- t ile only meanl oj cMt~ their _ _ 01 c::hIrge. 1 To..-nSG,rarnQllflthebltteoylrDmthe

_~i'IIo the ~Ind note the rudlng 1_ iNUItration 51. A.tum the ~IO the.:.llnd . . . . theeap 2 The rudlng ahoukl be In ItM r.gion 01 1 .260 10 1.260. If SO is below 1.200 u.. battery needs CI\argoOg. Note lhat SO II1'II vwy with ' '''''PCI.llurI; II Ihoukl be m... u.ed al 20'C 168·F}. Add 0,007 to the ...dlng for ... ery IO"C abov. 20'C, and SUblract 0.007 from Ihe ~ lor ffflJr'I IO"C I*ow 2O"C. Add 0.(1)110 the...ting 1O"f.ooo.e 68"'F. ar>d -...bI7.ct 0.004 from Ihe r-*'glor

~

SWIf'J 10"F t.Iow 68'F.

which hils ...... .nough hose

IIPIf1ln of • motorcycle t.tt..-y. • SpeciIIc: grwIIy II ~ • - . . . 01 the

"....-the fIrst.:.l cap. er.w

lor...,

3 W h.., 1M ~hKk is ~omplele. .In... IIIe

hydromelar thorougNy w ~ h dNn wltar.

'anll8 end conne<:l III pro~ across the banery lerminala. eonMCt the meier', ~( ..vej~,-...tyf'MI.tothe~..., ~

(.va) terminal. followed by the

mel.... negath!e (-'4) probe, usuaIy

t:UcII. 10

tile tM.tlery neg.oollV
"'_.

• The lerm ~ontlnu1ty d-.,:rlt.a tile unlnletTUpled flow 01 ale<:lrlclly Ih.ouOh an electricil clrcuil. A ~OIl l lnully cheek will determine whelher at! ope
......

• Conllnulty can be cheeked wrth an ohmmet.., multl.... I.., continuity 1. ., .. or bettery WId bulb I"' circuit 1_ IIuIIr.cIons

e,7_8) .

8 I.\.

W~

n.. fHM (JrOdut:w1

Lh spa"_ :::~"ior-_~·

In the WcJnIty r;>f Ute batfefy. ~ allow the ItIectroiyta contKl your skin or ck>fhlng . If It don, wnl! II oIf .mI-.IIIm~" ~ art_lion. • The specific gravity eh«:k IIMta an ~ of.~. 01 chIorge.

'0

_.

• A hydrometer II liHd lot mHSUring ....,.. grr.'ity. Maq

,,",)'OI,j~-

REF·44

Fault Finding Equipment

Continuity chock of Iront brake light switch using II mel.... • note spilt pins ulled to access connector terminals

•

All oIl,-lnslruments ... MIl-pow..,;!

by • battery. therefore thoe checks _ made with the IgmiQn OFF. • ,.. II safety pr9Cal.ltlon, Jlways dis<:onnolcl !he banery neg.atr.e (-ve) lead before making checks. partIcularly If Ignition SWilCh checks

.... boWl(! made. • If u.slng a meier, ..lee! Ihe appropriate ohms scale and check !Nt the meter reads infinity (..J. Touch the meter probes logeIr.. ...cI check Ihat meter reads zero; where NoCestary adjust meter $0 that it ,eads

It,.

,~.

• After using a met., always switch it OFF to cooserve its battery.

Switch checks 1 If II switeh is al faJAl, !rae. Its wiring up to the wiring conneclOl1;. Separate the wir. cornectOlli and Inapect tn.m lor security and condition. A build-up 01 din or corroslon her. will most likely be the cause 01 the problem • cletn up and appty II waler dispersant such

Continuity chock of ilia' brake light switch using II continuity telter

wireI wherMI COfTItWIetlon ~ like the ignItion IwI1ch. have many intMT'lllI IInki. Study the winng dlegram to en&Ur1I that you ... e connecting acrOIl the correct plir 01 wires. Continuity ~ow or no m8l!lsu.-bie resistance - 0 ohma) Ihould be indicated with the Iwitch ON and no continuity (high resistance) wI1tI" OFF. 3 Nole that the poIerity 01 the t$$t probet doewI't mati« lor contonulty checb, IIthough care should be teken 10 follow specific test procedures If e diode or solld'ltate component is being checked. 4 A continuity lester o r ballo,wy and bulb cin::uit can be used ~ the aame way. Connect III probel as dncribed above {1M Ulustntion 101 . n.llght should come on 10 indicate contJnurty In the ON swl1c1l pOIIIbon, but should extinguiIh In the OFF pOIIOIlOI'I.

WIring checks

ohm, • 10 scale and connect its probet

• Many electrical fau lts are cau.ed by damaged wiring. ollen due 10 Incorrect routong or chaffing on frame componenll. • Loose. WfII or corroded wire connectors ..... also be the of eIectr'i;..t probIerrIs, especiaIy In expoaed Iocationl.

&CrOll the wi," from the switch , ... IIIUl tra tlon &I. Simple ONIOFF type swilc,"-. such 81 bfake IIghl swllch". ooly have two

I A continuity check ean be made on • """'" length 01 wirg by d~lng It at NC:h tnd

_wo
2 II uaing II lesl _ . HI the meter 10 the

'**'

and connec1lng • meter or continuity tes'er acroA bolh endl of the wire {1M !nUItratIon

111.

2 Coollrluoty (low or no ""Iane. - 0 ohms) 5h<.>u1d be Indicated If lha wire is good. " no contInuity (high rw.;Jstance) II lhown, suspect a broken wn.

Checking for voltage

• A voltage check can determine whether CUrreflt is reaching a component. • Vollege can be cnecked Wllh a dc voltmeter, mulTlmeter HI on lhe de vohs scale. t"'1ight or buzzer {_ Mlustntions 12 end 13). A met... has the ~ 01 bang able 10 ..-..... actual voIta\Ie. • ....."., wing a met",. check 1tIatita leads are Inserted In the correct terrnlnala on the met.... red to positive {+ve). black to negatlVfl {-va). IncomIct oonnectIors can darnIIge the mIIt1r. • A voltmeter {or muhlm"", " ' 10 the dc volts scale) should alwsys be connected In parallel (ecroa the Ioad). Connecting It In series will deoJtroy the meier. • VoIt8Qe eheck$ are mao. wI1tI the 9nltion

0".

Fault Finding Equipment

1 First ,dentif)o the relevant wiring c;rcu~ by referring to the wiring d iagram at the "nd 01 this manual. If other electrical componllnts $ham the same power supply \1& are led from Ih.. sarna luse). take n018 whethBf they are working correctly • th!a Is uselullnfomlatioo in deciding where to start checlack probe to a good metal earth (ground) on the molor<:ycle's frame Of directly to thfl battery negative (.ve) term inal (see illustration 14). Battery voltage should be shown on the meter

. or • test light - note the earth eonneclion to the frame (arrow) with the Ignition switched ON. 3 If using a test light or buzzer, connect Ita POSrtiv8 ( .. ve) probe to the powe, supply terminal BOO its negative {"ve} probe to a good earth (gfOund) Of! the motorcycle's frame or d irectly to the battery negative (-ve) terminal (see IIlustl1lltI(015) . With the ign~ion ON. the test light should Illuminate Or the buzzer

~"'.

4 If no voltage Is Indicated, work back towards the fuse continuing to check for voltage. Wh&n you reach a point wttere there it! voIIage, you know the problem lies betWee<1 thai p<Wl! and yovr last check !»int.

Checking the earth (ground)

A S&lection of Jumper ww ... lor making e arth (ground) ohe<::ks

• Earth COltrieneed, check the security of the main earth lead from the

REF.45

negative (-ve) terminal 01 the battery and also the main aarth (ground) point on the wirlng harness. If comxIed. dismanlle the corn ecllon and dean all surfaces bad< 10 bare metal. 1 To checI<. the earth on a component. use an InSUlated jumpt'l!" wire to temporarily bypass its earth connection (see illus tration 16). Connect one end of the jumper wire between the earth terminal or metal body of Ihe component and the other end to the motorcycle'll fmmII. 2 If the drcuit works with the jumper wire instal led. the original earth circuit is faulty. Check I he wiring for open·c lrcuits or poor connections. ClfIan up direct aarth connections. removing all traces 01 corrosion and remake the joint. Appfy petroleum jelly to the joint 10 prevent rutura corrosion

Tracing a short-circuit

• A short-circuH occurs where current shorts to earth (ground) bypassing I he clrcuil

components. this usually results In a blown fu~

• A short-c;;rcu~ is mosllikely to occur wh ..... the Insulation has worn through due to wiring chafing on a compon ent, allowing a direcl path to earth (ground) on Ihe frame. 1 Remove any bodypanels neeessery 10

access the circuit wiring. 2 Check that all electrical switches In the Circuli are OFF. then ramove the circuit fuse and connect a test light. buzzer or ~tmelEl< (HI 10 the de scale) across the fuse terminals. No ~tsge should be shown . 3 Move the wiring from side 10 side whi lst observing Ihe lest light or meI er . When the tesl lighl comes 00, buzzer !KXlnds or meIer shOW» voltage, you have found the cause of the short. It will usually shown up as damaged 0( bumed Insulation. 4 Note that the same lest can be performed on each componll!1t In the Circuit, even the switch.

REF. 46

Technical Terms Explained

A ABS !AIItl.lock braking .~.I.m)

........ ~ electronICally COI'II.oIl«I.

......

whfIeI lockup dLll'ing bfaloog and

~

.._

A .ystotm. th~t

l'Iydfauk prIIUU" a' whMI wtuch IS

IIbouIIO """.

Ate ...... rIt.1

~ buI

ComIX"*'!S .... tat:>kl lor t"not ~ by !he rnotcrqcNo

"'"""'"""" I\exaoQnaI All.., k,.y A

wr8fICtl ..nd1

lila Into •

_~r.c.,

"'".....lIng cu......,\ (K) CurNnt produced by

an .U_or.

Rooq......

oon....-Mg to d...,;!

by • ...::t.n. far c:t.gong ~ All_or c:c.--tao ~ !rom the eono .... Into -..ctIicool __gy 10 chaige the balliif)' tnd po:rw. the ~ aystM'I Am.,. •• (amp) A ... nn oI ....auremeot lor the IIow oIe1ectt1ca1_t. eo.wr.nl_ "'ott. + OIl ..... AmpeN-hour (All) ~ 01 Dollery cap.cJty ~

-or

Chlrglng

Blckl.... The I""",n, of mov..,.,..n' betw-.

~

hMd or

IYI'.m

Into _

Ols.criptfon

campanan" which charg. ,he

Net'"

IwmIl..II

of

,.,.

""""y. II ,he

_or. an:! rwguIaIof CltcUp A rIng"tI\IpId ehp UMd to

W~ "'~~ofl....o.n.d ..... _ "",. fKe WIlli I"Ilr-..cI ..... _

_~

~lt-..two_

In '1'IOuIIng: In IlXIIn'IIII circ:tp fitlIn,O III"""" on th. ou!$lda of • cyhndneal piece aucfI . . . 1INft. """" """"'" .. a anap-ring CI •• rane. The IITIOUM of _ toM,......, two pIlrts. Fo- ",ampf •• batw_ • POllon and • . , . , - . ~ I baerfng_ 1)gumaI. IIC. CoiI"";ng '" ~ oj _he " ... found ...

_1IlII. ~,,"*-IOIjllllf_.

u- bIot_ two worI
Blaring.

10 prevent _

0I1he

~

and. bvIIcI·

up 01 MM. FOUl 'YP" 01 bearing ... c:ommonIy uMd on motorcyclft, pI"n ~I bNtIng" !HII bMnngs. , _ ' " rot . . bHri"lll and ~

.0:"_ ,.

"""''-ingI. _ _ _ u..d 10 turn Ihe drM IhIOugh 110".

TYPIC'I anall finsI drive and . . . . . - drM I_"tmionj

~I

movement of c:ytindnc:al pans "'" M ....... circ:tp._In.II""""

_

-.oua _

IhroughauI

IS h •_ I!)ringo'Ig _

I .....,...,...

tor .....-.pII

......oun in !hi ...,...."., _

In

vol.........

ComprH,lon

Reduct...... In and """-aa In or-..... .nd l....,pIdI ...... 01 • gas. CIUIId by IQI.IIIZing H InI O ......... ~. ComprauIon -.ping ControIt tt. ""'"'" "" ~_'"'*'hr!tlngl~ CompnaaIon ..1io Tha ....II<>nIhop_ cylinder voUna ........ "" potIOn II II top deId cantrw an:! ~ - . . . . _It-.. ~ illI

"-'>rIg

ma/Il

~

.....m.d CO
Angl._tlghtening A _ torque In _ _ _ otten ........... _ _exprllSsed _ tJghI...-.g IOtq... _ .....lor

-.

poIIutantl In It-.. _

B

t_~

bonom

dIad_.

Continuity ThI .......ero\4>Ied pett, In It-.. flow of \Ik!ocI:'dy.lJnIaor '1<1 ~ " ' * Continuity t.. tar Sa/I.powerId bIaapar or test IIgt\1 "'""'" lndIcIIas con\IrUty Cp CandI.power Bulb r.IJng """"""'" found

~"'C...." ' " Iyr. ~

Bri'.'"

BHP BrI~1 HorHPOw.. n.. ","su""'*" lor engl ... pow ... out~1. Pow ... OUlpul is now us""'1y "p"IISMd In k.,ow,'"

Ow)

81_,,,, tyrl SomIIer conslnlCtlon 10 rad.. tyrI. IluI with oue. bIIt ~ '" . . .-.gIl 10 It-..

..... An_u A'-"""I'*-'Y ~ gIy(:oI) m.xed WIth ....,"'. and ~ to 11M cooling

.Yllt..... to po-event r_z,,'O of the cooI,nt In

t_

WlOI •. ,'nt,I ...z. also conlalna ctlemlcala \0 inhIbit COI1'oaJOtl and 'N lorm-'iOn 0 1 and

01'* o.pos.lS INti would ,..,..10< _ coolant

-..-., AntI-dM

~

~

10

"* the

cIoIiJ

....,

...,;juc.

Anll-Hln compOund II coallrog lhel ...,;j..c. !he I'itk 01 M
to hogh '...,l>«8lu....

wen u

,.hauS! clamp

~

API Atn.k;.., P . t . - IMtrtutl. A q'*'lr stInCItItd Ior"~ motor oiIL ""....,... A natural ~bf'ouIc ......... W'I\h grM! ,*1 commonly used ~ the

._tance,

~oIbfakelr\ction""I""""~

'-"" hazard _Ihe dull Ct . .ted by~. sv-t_ -"ouId _ be _ or ingeIted.

~.

ATF Automatic

T.~

FJuod. 011... ......:1

Inlfontl_ ATU Au\otnabc TO'I'Iing UnrI. MedIIrk;II"""'" !or adVancing the 'IiIM ..... timing on ..,.,..

.....ATV AIIT........

V~Oft.-._.Ou.:I.

....Il0l play Sodoe-l<>1OdoI--.t. ....1. '" anall on wllo:lI I w'-I ,evolv... "'110 ~nown .. a opir>dle.

fined

,.,. ,ea, whlll and lil'\ll do ..... to . _ t.... n.mi..1on shocks 1_

ba '", ~

sptOC~ . .

-I

n..

bIIrIng ... Ihe erMI of It-.. !hM', IttachId to V. trriI/IefI.

...........

.. !rom",

B_ng

n..~~.............ng

~ydrau l >C

II'SI .... vls • Dlesd nipple 0< Dlesd

B ottom-_ '" ducrlpI.on Of an 1<\0...... cotnP
etan""-

~

BTDC BIIIr::Q Top DIId

at\KtIIId 10 Ihe Iork ~ IItg

{IIIdtr) IOptMWll!ott. cI
......

~.

Il10_ boaIrinO

~"'II1Od

TYN plies ..angad in •

........ Ueuallykuo- . . pfiaa..-l.

her>OIlPfI 0- 8PfI in tyrI.a. 00dIS. Cum drln Rubber dlmJ>lf Mgmen ..

c.m.., ..... of ~

P<*iOt\ VlItO'I *'-G II of*! ~ In . . . . o f . . . , . . o r - - . BTDC. Bu'" '" cytindnCaI ...... , 0< t'Ubbw eotnpOf>erII uee<j DaI_ two moving patU. Burr Rough "'gI IeIt on • comP
Cum drIY, rubbel"ll dampe
tr ....... lssIon anoc:k8

.....n.

c

o

cam chain n.. d'ofIn _ _ dfiYI from V.

e.g,"

lt(s). ClnI.ter The"..., eotnpOf>erIIln '" .... aporative erniuIon control *1'..... /CaIiIot'I"OII onIv); coni.,,.. ..:t"'"ed charcOll ",.nuIII to If8/) """"'"' frotn It-.. li.oii ...... rather IIwI *"""'IiI

CloclHyPl 0". _ adapt .... tor ..-.rinD n.onout an:! ~on poertIon. &~

"*""

"-"10 -n 10 It-..~.

c.l.aat.d ~ II-. ~ *"'lIlt-.. lop of. c.tJe ..... For.,...,.,... I ",..",U"'" whaeI axle or spndIa nut CI'IIytlc convll1ar A davoca fn '!>e 'xllllul! eysl...., o f _ ~ which " " " _ c;ertMl

eIIK

C.hbf'ted d
poistonP<>""Ion,~In~.

Dial

~

In"...,., Of InchaI. Diap/'nOm The rubber "*'">br_ In • 1'I'IfSI. "" upper

--

~ Of ~Of whidI ...It

Diaplngm ~ '" a-IQII """"" ...... oft.. ....... inWchaI. Di'K' e ....... , Ide) Curren, produr;«I by • de:

-~

Technical Terms Explained o.c,rbon ...tIon

TIMo

~

01

,~

c.bon ~ • 1Y\)Icdy from !he oombUIt""

.....

~.----~ 0 ._ o.tructivft _ ""m.cI"'II _ _ _01_ of c;:on...~ """"_ ....." . bo,mjng . In combustion DIocI4o An lMetrical va"'" which onty anow. ~ to _In ..... dnc:tion. CommonIy..In rooctIfIers _ t!arI ... lnter1ock 1Iya_. DiK valve (or rottory v_ ) A Indt.IcIioo1lySlem _on.",..~~

e

h

t

<

o

f

_

~

-

.

.

.

.

.

.

o

w

t

..t ' lowd _ _ \DOHCI An.-.g;n. __ ...... _ _ .-.d_lorthe_ . . ~ A ~ btI!..-I 10 I1IOImiI drt\oe

f'"

10 In. W"'" on __ mo'Ote)'cl ... I\, drl • .c..Ii .... al.o been used 10 dirt.... II>e

-..tta.~""""""""oIK...w. ~ Any 1hafI.- to nn.tM mohOn. Commonly . - when ~ 101M final ......... on ..... ~~

E Earth return

n.. Ntum path ot WI eIectnc.l

circu1t. ut-.g the~'. "*'-.

IEC U (ElKtronic: Conlrol Unit) A c:ompu!. .,..,.,.. conttoIa (lot ~ . . Igr'iIlon 1lyaWm. Ot .........Iod< tIrMInu syot«n. EGO Exhaua' Q.u O. ygen...-..or. 5orr'!eoI, ..... <*1«1 • L.¥nb
A

~~~whdI~the

....."''''''''' !wi InjKtoon _

\tie igMIon

ayot .... In an

!no:IIIo.I ,...........,.." of Mngthways ITICIYei'\'\fII t . t _ two I*b. N; 'pP~ to. <;rriWfI. \!Ie -..c. 111M !he cnnkshaII <:WI _ .,.

-----

A ~ haYing 1'10 jootwIg Ink. Common u.. lor cam cr.-.. _ IInIII _ _

!P . ...... ) ()jlItj)I)IiMI.IIUCl1 'YPigh .......... h _ _ tho,

~.

HIHcofl

f,"""" The........w of _ -"""I'-=tIorI tal!.~ . The ~ III. -.0-. or ... ..-rItIIy of JItfb, _ ""' iI'"IiIIIII ~ of ""'" _ actIMI - - - . . : . For~. ""' d~ the """ 111" .... pedal ........ I)Itfor4I the .... III"Ike iI ",,' ..-.d. f .... lnJectiorl The mlxt"'" II..,....,; eIIctRInicIIy _ dirIICted into the engne

on.

ru.v...

~

~

InJlCllorll or

lnIo !hi ~ (~ ~. SInIcn LIPQI)r irIItwmII"", "" (IndQct

...-.;tr.opeC-~

fu.ualr mi d ..... The ch.,U' of /VII _ .Ir going Into the See StoIc:hIonIItrl mIa. Fu. . An eIIcIr«:.I dIvIce whiCh proIIctl I arcu~ ~t ~ PY*1oed. The typicII

..-.one.

fuM _ _ • CII~tnt.,

.ott

~

10 men II •

of mIIII whiCh iI

~

fIow~.A'rIP'I

current _ _ the<*o.lll.

G

O. .k., Any tntn. soli ITIIIlerlll - u.... Uy corI<, Clrdboltd. am..to. Of" toll ..... ,11 - instllltlCl ~ two metlllUI1_ to _ •• good _ . For - - . the cyIb;Iw _ gIIIkII'" !hi joint ~ '''' bIod< end thI ~

.a ' U1j1

An instru......t ~ dl.pley used to monitor "'Oi"" cond~lon •. " oa~ with • ~ pointef 0t'I • cfiIj or • fbced ocaIe II en lIIug1· " 1IIug1 _

• .........tcII

.-:Iou! II CIII8d • dlgr!al1IIUQoI. o.. .-tIoa The ~ IWIio of I pair of goare ... gawt;IcI>;. CIbIat«l "" IhIit ro.mt>et of IMIf1. OIIH-bwlinll _ HonInsI Orlnding Pfooeu for _ i r I g the V""" 18Cf! and __ ~_"'thlC)'IIrIdtIr_.

emIMIon

control

. ,..,....

d>In:::oM.., _ _ whk:h_

*'"

fuel wpouro from !he rathw It\IiI'I allowing them 10 ....." to the t!~. lJauaIt)t only fttI«I lo Cali' ....... modehI end ~ 10 .. an

£liN> IyStem. EJc~naIon c Mmb-to"

s.clion

of '_Ifob

...... _ I y I I .... ..,~IO~ ...... -=-OCY.-.cl 000II pow.-

0..<1I/l0'l pin The _11 which connact. thI oonnactIIlg rod _ wit!! the piaOfl. 0I't.-. <*lid • pIMorI j:WI or ~ pin.

H ..... ~ GeIr I.-h

produce _

~

_1IisIhtII' CU'YId_

..... _

-

"~'-

~ 10

lid ring bacIding-tI.

"'"-

H y d r _ An ina\l\.O'Mnt for !T--.urIng tIM .,.;IIIc; gmoIty of. -..od bIIt.-y. HygroK oplc Wal"" abIortIinO. In mOIOfC)'Cl1 ~ bfakIng .mdIn<:y will be ntd\IC.cIlf DOT 30<. hydrUicftuid _ _ frum 1M - "... ..... be tIQn to IoMp . . . brake ftuid

_

1n1lghUy....-.cl~

n Pounds·force ,..t. An

euct

Pound_~

torque,...,..,

_"'*

~

,_.

by bell

combu.tlorl ch.mber d .... to 1ncor1ect ,tert'''!!

-...In-b.

Mllnt at O>crNSlng thl

l"nlUon . dvanee

Iming 01 the II9'Irk .t high .. angina 1QIId,. Dona by ITIICIw>iCIII ........ I"TUl 0t'I e.ty ~ 01' -...nicIIIy by 11M ignition CIIIIII"OI 1Rt"" ...... ~ Ignition ~ The I'I'ICII\'WII at wIlid'IlIM IpIr!c plug fitM, tl(pressad in the number 01 ~ degr_ Del"" tha pillOfI _ tha lOP of Its """"".orlntha""""'*oIl"1'1i111metrM~1I'III

piaOfl_IMlOj)ofltslllrOka. Daactlptlon 01 en ~

Inllnity I...

aIectricII_._I'IO~""'"

_ e d , _ fupMIa

or

~

tubal or

_1orI<~

teo- ... held In IN )'OkII _ II~

....

The .....

_,..:1 lOt"-thI_ fori<

ax» (~). L_ ..-.prung.....ogttt and ..1Itr ~tt.n~k:wb..

J JASO o..Iity _ _ for 2 - _ " . Joule The IRt 0 1 _ -uy. ~ The ~...-I_ of • .n.I1.

K MlChIn~

"-"I 01 turning IhI

~ ..........1Id

IWlld! lot

-oencY ignibon ""t·out, Cuts !hi 19nitiorl cin:u~ on .. modaIa. and add~""1Ii1y - ' stan.. motof operation on ..uw..

kin S~ lor kiIomIt,.. kmh ~ lor IdIomIInIe pal"

Firing order TIMo on.o In whl<:h the eng,ne

cyIInOw1. ' " . or 0.11'0 .. theif pa_ .trok .... ~ willi "'-......t>tfone cyt;ndIr FIoocIng T.",.- to -=riboo. high " - ' _ .., ""' ~ IIoet ~.1McIirig 10 "-' cww1low. ....so ...... to el
01

to~_.~_

torqua II - " , . ~ Ie ~ lot int"""atld 0rcuIL

KI. Iwltch

, ............ o.a\ptlon 01 the _ _ !rom the IIwwniIooiIon 10 the _ whMI. u.u.IIy by en.;.,

or ~. buI

1ndI. IvI itnptf\II unit

"'--

I ~.

_Io_"'''-''' __

imparill uI'IIt 01

1OIqUe.~"';-'.It_

Ibf In

engI ... OVItr for .,-,lIng P'JrpoH!I. Only u_'1y finad to ITICII*k. ...... capacity motorcyc;lal _

A~.tripOt_of

II.... ground to In

_ _ IMgiIZII

HT (High T-"on) o.tcrIpI;on of "'-1IIectncII t:rcuh from tha HCOndIIry wlndirlg oItha ignrt.... coil to the IIPark plug. Hydnuk "Iiq.jd filed tyStIrn ......, to ~ Il< ...... ... from "" OM ~ I to ~t... eor.wnon moIorcydaa _ _ WId

Klckltart bIadooor~

to

1IrIIgIIt-alt gaat'L

ort.I.-Iotpm...y~

F f ...... _

HonIng

eyIindtf boQ (liii0 ealltICI gIu"'_IIIOI, CIn ...., bit carried out to IOUOI'*I • _

lbl

Gep The diltanee '''' I!)Irt. must ira.... In jumping In:Im thI - . . .tocItode to the _ ellclroOI in • - " plug. Also ...... to the dIItanee bllw_ the Ignitiof'I rotor WId the piclIuP coil in en eIecIrcric ignition rysl .....

_~

""lnthe~

EndIaM _

"thrIId ~ r.paIt lyet...,. Commonly uMld as • "pa~ lor stripped I~ plug ~ (_ lIualnlllonj.

f ... ItngItI The _told _ . of • compOneI1t wh.., m...ured. CMch. vII.I mr>d lorI< IP~,,!! length. .... ~ . , (est. w~1IOuI Iny

.-

REF. 47

ft(u

L In, "'I'ng • Hellcoll thread 1nMt't1n • cylinder lMad

Lambda

P.I ......... " .......

fittad In tIM

""'_ust Iyst..., to .......url \1>1 ex"'ust 0" ""Y'51«I_lent (eXCIM'" tacto.!.

-REF' 4.

Technical Terms Explained

........

~hon tor UQuod CryItaI 0ispIIry LED Abbteviat"'" tor Uo;JMI EnuItilIO Diode. 1.1..... A , I . eyl,1\de( loner lnaertll
LCD

LodL''- n.. lugs ... Ihe _

tr>pIe

a.mp

l'tCI
canIKt. lock ... ."-r A lorrn 01 __ he< designed 10 ~1 ." attaclling r1IJ1 !fOW*' ..... pply 10 !he primary WMIdng 01 It-. ignoIion coil ~·to-lueI_

u...

--_

rlngl

The

M,lnt.."nee-" "

~ngo

....

belw-. thoI

(MF) b. tt....,

bMI..." which cannot be lopped

Minometer

A_led

"p.

Mereury-!iHed CIOI'brated llibel

UMd to - . . . kilt .... ItKt~. \)Mel 10 .~ carbuNtlln on multl-ql....

M\co'omel ...

-...........

Pul.. ..c_.ry air Injection

Of

(Original

Equipment) R""" 10 compcfW1lS titt.t to. moIon:yc:Ie . . IIandInI or~l*'-~byChls~

--

Ohm n.."""'01~""""'.~" Volls C<.nw!I. Ohmm. I., All Inll ",mftl\1 lot ...... wnng

A~~~

that mMSUf'ft componenl DUlS>CIe 11......1l1l1I

( _ III",Ir'ation)

ang,'"

..-_ ..t witt..

Tappet shims . .. m!C
T...... I... ~~ T)IIIIQIIIr.-1or

..,.;;ng Mg .....0. 01 • -"*' material: in ...... the O·nng II

~

o.-.i~, (OS) TIIn'tI o.tMCI for poalon _ nng linad 10 • Nbortd C\'fIn<* Ow..t.ead urn (.oI>c) engi... All engo". ""Ih .,ngla " " rnoh.h 1.....1.., on 1"lI o l lfle cyhndar

. . . opOcna

....

"""**

Plu lillBUg' It Ihin "rip of plnlll: thr.-d IIVIIIabIe In d.n-c I/UII, ......-d tor ...."""'0 ~. For ......... .v1>oI~. IoIId IICrOH • )ournI1 The parte lite ......,bled and dwnat1I'-1. Ifle _ 01 Ifle

-'no

crusllad Sirop ,ndtCat.. 1!Mo

cl, ..anoa betw....

(ground). delemunad by who:/\ ball.., 1M
MonoahocIc A 1WIgIoI--"", UM IrIIung IN ~or _ _ """tolhe~ mph - . o n 1or_1* I'geS [,om $.I\EIO when cold to

SAE..a_hoI.

M _ M Il8cttlcalIeM w.uum.nt .... oIhh capablbly to ~ \/0111'0-. curr.rrt and _tancoo. Some rnet... ...., incorporat. I oonIlnuIty _....:I ~

~ . . ~negn...­ 4 aotuel_ - , * , the

Pre-Ignffion

lueII"r

-"!Lv firu. 0Mn d... 10 I hot spo1 In In. com_bon ch.Imber caused by carbon fKJLItI·up. Eng,,,. ltondency 10 ' ..... -on . ..... ·Ioad (~j Th& "'""""" allpring is ~ wn.n In u..........- statl. Pr.rood can be applied by 11M. IIpa<;er . . _ a l rnuctuf'I ~ _ _ " "

_.

h., •

Th& method of eng.i<>a IubnCll_ on oIcIIt two-stroke eng ..... Eno""" 011 Ito ...... ad Premi~

N

Wlthttlepe\r<>llnllW!uai ,*",., ,",*,I'k: rib<> 1""- I"",ojl ml~ I• .omaI"n. . rad 10 ..

NMdt, rolie. bearing Inn .... ace 01 caged JlMdIe ""ien ~ hatOloned out. rae"

-peI1OII". Prlml/l' ~ of Iha drive Ifom the crrisI>ah to Iha du!ctI. ..,....,. by ~ .. cn.t PS f'ladesllrlc, - 1 Gennan interpretliion 01

~01...-....god_"""",*,belo\.f\d ong'n.. Commc>nI)I used In reM ~ ~_ ...0 In two·stroII,

on _

...-.

I~h....

boJib

4_ lIh.. trMIonj

~1nto'IiJ'OO'I'e\o~ChIs ~

""ooI .... ,Ih.WIQIe~."II

, ..... _.".,. to kooCII.

_a

r"..

....

PSI Poundl-IDnlI per Iq..... Inch, Imper>aI ........... _ 0' Iyrl ~ .. and cyIondet

N,t~,

A common '<»Ltc

~roj

""0'01" al hlg,*

pOlMlnt ...."II..:! by

ttIe~

(high resist"""). O-ring 4 typt of NbI:>er·Ii~'

MON (Moto r O<:IA". NumbeI1 A...-... 01 •

Ox_ of

~n

~bya~_

~ ""'" mrot\lIo PO*ition. 0pen-circuIt All -.etotc.l ccndtIon - . _ _ Ie • b<eak in Ifle !low of -.etricity - roo contln\ltry

)ournaI and IIMnng PoIl rlty E~he< negal,'" or flOoll,,,, .. rlh

NOx

Q Ou_

eng''''

p

---

inlO the ~I por!I.

~

o.ra- _

"''''''

A

_us!

Oil cool.. Sy'tem for diverting 011 outside 01 Ifle 10 • radi.tor lot cool"'D

~ _1cmI engine AII . . . . wIIh ChIs " " - iocIITad in 1M ~ "-I. but ..,tII ChIs _~InChlswvr-I*:dc .. " ' - ' It o.vIc>e iIW3Ied In IhIs oys'-" _ . . - - the ~ o;QI1len1ln U. '~U$I and con....". INa lnIornuoloon InlO an _.,....".AtIoellle
~011

.~. I.m

"""'"' 01 promoting IIW burnifIO of _ fuel poW«l\ In IIW geSU by rouIlng ,..., _

011 Inje<:lion 4 .....1.... of lwo-sltol<e ~ UIf\CahOn - . 01 II _ _ '-I to ChIs .......

M

M ~n

o

0"..... The ....... ~" 01 a fu"'s _1,,-rICe 10

-~ PTFE PoIy1et"fl~roIIhylen,. /I.. low frlcllon ..""lane..

R RecIt·_-pInIon A pinion gear on ttoa..w;l 01, .....h 11>11 mat" with 1 rack (thri< 01 a - " " whaoI--' up..w;l iii
_.

IncUchopar1llO'lg~

R..:Ii~

play Up and down _....menl about 1

Radial ply 1)1," Tyr. pilei run acroa I"" lyre (!Tom bud 10 bead) and ..OYnd Ifle ~0IIf1eryr8. ~ """...., lo\rMd ttisIOrt>on IhIIn _ tyno typea. RedtalO< A iIQI,nd-I<>-.... ' - I

dMIgned 10

t.o.-

It_'.

cIotwoce

Ifle 1~lur' 01 Ifle

0CI0Ir0t ... iIqIMI 00DIad engna.

Rae 4--"'0I--.ggllCll'l'llllry-v.~ 0I1ha Il~ "-I In relation \0 Iha >WtIcaI 4_ Mlustrationl·

Technical Terms Explained ~= ~ ~7.; ~ ~"':u~ac": :=I~,:,:: Nec .... itates 1M use of 0_....

~I!O
an(l

rings.

:::01~:~'~m!~~m,i~;

REF' 49

V

parts 01 ... 10 1 pari offutll SUlphuric acid The Iiqufd (electrolylll! used in a

Vacuum IIILlII" CI<>ck-ty~ gauges for """'5ufing intake nact .aCllUm. Used lor

~ad·",,1d ban"')'. Po'5OIIOU' and .~I'emeIy

caroor.lto< synchronisation "" mu~i-cyhnO$t engInM. 'I ..... A _ througI1_~ lhe!low olilquid, gas or vacuum may be slopped, started or MQUlau.d by a mo_bIe part 11\0.1 opens. """II

Rebound cIIomplng A """"ns 01 controlhng I", ~ of. ~...,;r spmg all .. ~ has _ comprnHd. AMi,1S 1M SI>'In9", nalural l.....oancytcbounoeMckafl.. bengcompr_ Device tor COffl«Iing !he IIC ovt;M of

Surf..,. ~ (lapping! ProeMS to comICI.

:'':~-;:I~in~ ~nd~~=:"'monIY =U::'=:;:'::~I'''''''IIlhe chargjng

T :;~I"'~~:~~~or.':'U':1 ::.: T.P*<ed·rol .... bearing Tapered inner rac. 01 ~~I~r=.....~~ ~= ::"w,""" the

Recti'.....

vo/Iage Iran 1M

geoerm... or a~emalCO' wlIhIfl a

specofled range. ~I.y A OIIo<:trIcai _

to switch _vy cumont on and off by u."19. law currenl .... iGary CirCUtt. R..lalanc. Measured In ohm •. Ivo eI""lrical component'. abUly 10 pass eleclnc..t current. RON (R.... rch Octane Numbetj 01 • tu.! •• ft$ist""", 10 knock rpm ~""'" per "'nute. Runout The amount 01 wobble Qn-and -o
"..--e

s SAE jSociaty 01 Aulomolivo Engin .....)

"

stanMrd tor 1ha vIxosity of a nuld. Sealanl "lIquOd or pasta ..sed 10 Ple,,",,1 laal
<:<>c""" with • gasket. Senrlea IImft Torm lor Ilia polnt wll6re a compQn""t ,. 00 longer u_ble and must be

......

Shoft drive A method of ~ drlva from the Ifammossion to !he .-- _ . Shell baarinwo PlaIn bMrIngs e<>n$ISIing of two """II hal_. MOSI olten u* U blg·end and ma,n bearings In a I"",-stroke 6010,ne. otten caDod bearing IJtS«IIl ShIm Thin _ . commonly used to adjust the cl ....aroce or ,.Ial,ve PM,l ions bel ... """ Iwo partll For .~. srotn. inMrted into or under tappa(S or ~ 10 control valve clearances. c-..co is adjUSted by chang"'ll tI>e Ir.ic:knea oIt1>eshim. Shon-clrcult An "'ect,ical condil>oro wh",e c",,""1 lo ... rtt> (ground) byf>O$$Ing lhe arcuot component •. Skimming Process 10 correct wwpage or ropaI' • damaged SlMfaoe. og ." to-akol dlaca or aruma.

""orI'

Slide-"""",*, "apecioll pujl« Ifllll II(:rfrWOI Into or hooI<s ",,10 8 componenl such ... I _ft or bearlng: a hea"Y slld,ng tland le 001 lho .hllt bottoms agaiMt !he end 01 the stWt 10 I<nock the component fnoe. SmoU-er>d boaring Thtt tlaarlng In lho uppar end 01 Iha cO
-~. SpaHing Damage 10 camstIaIt _

or

bearir19

joumaII shown as 0'11011\1 01 the .....-IItttory. A ..............8 01 the electmlyt8', donsoty comparoct with wBler StraIght-cut 11'''' Common IY?'I gear ueed 0<1 gearbo>; &IIolts end tor oi I""'P .nd water po.mp

char""

"'-

Sllnchlon The inn .. Ihding part 01 Ir.. 1'''''1 forI< •• hold by the yoi<8s. Ott"" called a iorio lube.

COfTCSMI.

wa<po
r.e.d..

caged.- roIIon;.->d - - , a tapfJred outer raca. Exampl"" 01 tape< ro/Ier bearingo can be found on oIewing ~ T_ _ I "~ oomP'>'*" """"'" tnInSInIto moUon lrom Ih. cam 10 Itle vo~ slem. 8Ilh", d,""'11y or v,. a pusl1.od and .....:kor arm. Also called a cam Io/IoW8r TeS Traction Control System. An ~ controlled system wt1jch - - apir1 and rwducesengine ~ 1IC<:()«Iing1y. roc TopOeadCentte _ _ lhatlr..pist"" la at 115 highest poont In !he cyIir.der. Thruod-Iocking compOUnd $oIoIion appIled to 1~"ln.. Ih.-..ds to prevent slac~enlng. Selecl type to ouI1 applicalion. Til",,, ..... h... A wao./lttr posiHoned betw...... Iwo moving compQn$(110 on I Sh811 For ""ample. beI..-, gear pOnions ",,~. TIming cn.in Sse Cam Ch.ln. TIming light Stroboscopic ~ tor carrying out ignition trrung cI>eck3 with the ""9"'1 .........tng. Top_and A o;Io$crlploon 01 an engine'. c~111det IlOock. t--.:I and ""~ lIN' componIII1l$. Torque T.......-.g or IWistong Ioro!o about 8 shalt. T...-- Htting A pr..:ribed 19'>fnMS SpOCifIed by the motorcydo monutactur8f 10 .......... that tI>e t:o/t or nut la..".,ed corr«:tIy. Un<:IM~ong C8t' resutt In the Il0l1 or ne o;omponenI beinQ ...... ned. Ton key A 1Ii'-P'JO"I wrench. T.-- A stnps of a HC<>nd colo!.- ~ to. wire Insulator to d"I,ngul"" lhol wire Irom another POe wrtll the same colour insulator. For e.ampia. 8I1W is often u* to 8 brown insulator with • _ trac«.

vllva .'&nIj and 11>0 foc~er ,nn or lappM/loHower. The va lva

val •• I.p (the end 01 tile

cI8ararIce ill ..-urod When the valve .. closed

The """eet _ ks imPOr1anl . II 100 omall th. valvo won·t close fully and w,1I burn OUI. _ WIOO targ. r.oIsy OI*ation ~ '-'~. 1I.1Ye lilt The _ • """"" iA iiflld of! III - ' by !he camshalt lobo. 11.1.... timing The .!laC1 seltong for ttle openong and clOSIng 01 ttle valvolln .... allon 10 piston ~ lIarnler

catlpsr A P"""SIO/1 measuring ,netrumenl thaI maawres inaida and OUIS",," d,m""sklnl. NOI ou,le a. "",curate U 8

mk:romeI..-. but mortI """"",,lent.

\liN 1I.nc,- ldentilicalOOll Nurnbfor, Term !of the toik8·s""9"'landff_nurr-. III'coslty Tho th"~nellS 01 • liquid or Its ~ 10 flow. lIoh A unit !of e~ eIectr\eaI "tl
w Water pump A meclwncally-driven device tor 1nOII"'II c<>oIant ..-0U'Id the engine. WIlt A unit for e' p'ftS$'''II eIoctoic81 pow", Watts. vo/to • euIarrt I_ illustration)

_8

Tra il A 1~lu,e of $I_lng oeomerry. DIIlance from the sta.ing head to tI>e lyre'. corrtral """,;oct pont. Tripla Clamps The cast components wh'ch ext""" lrom It1e st-"'ll r-d and IUpport the loti< .tanC/'OOrO$ or U-. otten called lor!< yoI<es. Turbochlrg ... A centrifugal ",""ICe, driven by ""h~u.! gaSOll, tMI PI"""",; ..... tho Intake air NormaIIV used 10 _ the pow« output lrom

""i.

a

~ «'Oina

Wet liner amHIoemenl

dosptac:am.enl.

TWI Abbr""latk>n 10' Tyre Wear Indicator (nd;cate. the Iocat"'" of tt>e t,oed depth indicator

-~-

u

Un"'-I joInl or U-joionIIUJl "doubie-p!v<>ted conneclion tor lransmitting pOWer from a drM'og to • driven &helt Ihrough .n angle. Typicall\l Iot.nt In $haft ~ ...!llllTlbliM. Un.p","iI welghl Ivoylhlng root IUpported by lho bik8', 'U1lj)ONloon (Ie lho wMel. 11'1'''. to-akM, Iinal drive and I>oItom jmov,"II) part of the SU$peASiOn).

_ba..

eM"

Oislance from !he of tI>e Iront _ 10 I""contreoll"".- wheel Wiring _ or loom DMcrIt.-!he eiectrlcal _ running tho lenglh DI I"" motorcyc le afICI &nC105&d ,n tape or pia_tic _thong. Wlrong comong oft tI>e main tIarMsa ks UO
... asub~ Woodruft ~ey A key 01 ......u-orcular or _ 8 u* 10 Iocat •• gear 10 a shaft. otten Ulld to locate the Ilt«nator rotor on tho

oect,,,,,

"""""

Wrllt pin Aoott>er ......... ~

tor g.udgeon or

pi111<>"

REF'50

Index

Note: References throughout this Index are in the form - ·Chapter number" • "Page number"

A

mat>WII - 0.9 Ackno~ ...... b - 0.9 About thI,

Alrfltl ... eINning and rer.waI - \ ' 12 ho!.osInQ removat and installation· 4 06 Alrnu.l mixture adjustment IJef*lIllnfonmotion - 406

.......

,~

bruaIlM reMWaI- ' 02'9 ct>eck, removal and Installation - 9 023 drive ahalt removal,lnapectkln and NtaUation - 2056 AsbHto. - 00 10

B

a.tt..., ·0010

choke - \ ' 19. ' °21 EXUP !JV'St." - ,.023 lubrication - \ ' 20 ~ ... -9·

'l

throtUe - \ ' 19, ' °20 caJiper.l removal , OYe
C..........

el\llrging - g •• cheeIc - \ 017

removal, installation. inspection and maln\enar>C\I - 9' 3 Bleeding

brak.·7-,.

clutch· 2-37 Bodyworlr - 8' \ et Mq body I*'*' - 8 0 2 /airing - 8 0 2 mirrors - 806

disusembly, ~ and Nper:tion - 409 overt\a~ general information - 4 07 reassembly and Il,HIIlellei check - 4016 removal ancIlnalailallon - 401 separation and joInl""" - 4 0 14 synchronisation· ' °1 0

C_

check. adjustmtnt WId IIbieBtion - '°1 lubricant - \ 03 removal, cIeoIr*lg WId inIItaIIatIon - 6025 Charging .r-tem leakage and output test - 9023

~-8·8

seat cowling - 804 ""'" - 8' \

side COY«1I - 8°2, 8 0 4 wln(lshleid - 806

Btake "uld - , oJ cIIange - ' °25 ....... ct.ck·001J Bnoq,-. p/pNand ....... 1ntpKtion and.-wal - \ 021:1, 7013

Snoke ...... removal and installation - 6 06 Brakallght check· 90S lwit~ check and l'WMWai • g o\ 0 Brake peds W8ar check - \ ' 18

Brake pem.1 rtOmoval and Inslallatlon · 6 ' 3 Btak•• pt...... heck · 1018 Btak.tblllight bulbs . - 8 1 - g. 7 a ...... wheels MKlIyrw - 7°1« '*l bIMding btake system· 7° '4 brake hosa. P'P- and unions • 1' 13

calipers· 7" , 7- \0 diacs - 706, 7011 master~·7 '6,

c

c. ....

7012

pads· 702, 7 09 tyr.. - 7 0 21 wtleellI- 7o, 4,lo\S, 1018, 7017, 7" 6

t""ting ~ information and precaulions - 9023 Choke cable - 10\9 removal and Ins~tlon - 4 021 Clutch chectI - 1011 Clutch fluid - 103 bIae
Clutch ma.l« cyUndar and r"ease mecllanillTl removal. <wemaul and installation - 2034 H81sreMWal·l 025 Clutch removal, lnapectlon and instIIllatIon - 2030 Clutch ,witch check and .-wal - 9 011 CoIls check, removal and installation - 503 Connecting rod ~ generalinformalion • 2045 sheI seIectiOt1 - 2046 Connecting rod8 oil c~ cheel< - 2046 removal. Inspeetion and installation - 2045 Contenta - 0 02 ConVl!lrsion FectOfl- REFo20

Index

CoolI.nl - 103 Coolant hoses, pipes and unions 'Ol1TIoval and Installation - 30S

Coolant level c heck - 0' 13 Coolant rsse .......;. removal and inat.lloItion · 302 Coolant temperature gauge and sender chock and

renewal - 3 04, g o13 Cooling fans and oooling IIlI> s witch check and reo_al - S02 Cooling sys t&m - 301 81 SiIQ

clleck - " '8 coolant hoses, pipes and unions - 308 cooling fans and cooling fan swrtch - 302 dnIIoing, flushing and refilling - 1024

pressure cap. 3 02 radial00' - 3 06

f'9S8I'VOII"-SOZ temperature gauge and !IeI'Idw - 304 thermostat /loosing and lhermostal - 3 04 water pump - 3. S Crankcase halves Inspection and servicing - 2043 separal>oo and reassemDly - 2041 Crankshllft and main bealings removal , Inspe<:tlon and

installation . 204 7 Cylinder block removel.lna.pection and Installation - 2026 Cylinder compression check • , 030 Cylinder head d"1Sll$Semb/v. Inspection and reassembty - 2022 removal and Installation - 2'1 9

D

Daily (pra·ridtJJ chocks - 0" 2 8'1 seq brake fluid ...... chock - 0. '3 clutcn fluid level check - 001 5

coolant level check - 0013 8Og1ne/traosmlsslon oil level clleck - 0.12 final drlve - 0' 16

fuel- 0' 16 legal and safety checI<s - 0' 16 lighting and s1groalling - 0' 16

safety-O' IS $I..OSpeIlsion a od sleering - 0' 16 lyre care - 0- 16 lyre checks - 0 ' 16 \yf$ pressures - 0' 16 tyf& Iread depth - 0 ' 16

Dimens ions and weights _ REF' l Discs Inspecti.,." removal and installation Iront - 7' 6 rfl&t - 7' 1 I Ortve chain check, adjustment and lubrication - 1' 7

lubrlcant- 1'3 r&mOVal, clMning and Installabon - 6 . 25

E

Electriealsystem - 9' 1 fir seq a1temator/regulatorfrecllfier - 9' 23 battery - 9. 3, 9' 4 brake lil/hl!l- 9. 5, 9. 7, 9' 10 charging system - 9. 23 clutch switch - 9. 17 coolant temperature oauge - 9' 13 hllJ~ finding' 9 ' 3 tuel pump ... ay - 9' 16 luses - 9' 4 handlebar ~w~dIes - 9' 15 headlight - 9 . 5, 9 · 7 hom - 9' 16 Ignlbon (main) swllch - 9' 14 IocIIeator tigtlts - 9'5, g. g instrumenlS - 9' 5, 9' 11, 9' 12, 9' 13 leakage test - 9 ' 23 licence plate light- 9. 7 lighting system cl\ack - 9_5 neutral switch - 9' 16 number plate light - 9' 7 oil ~veI sensor - 9' 16 outpUt leSl· 9' 23 regulator/rectifier· 9' 23 relay assembly - 9' 17 sidelight - 9 . 6 sidestand swllch - 9' 16 speedometer- 9' 12 start .... drcu~ cut-off relay - 9' 17 starter motor - 9. 20 starter relay - 9 '1 9 tachomi:ttl)f - 9' 13 taillight - 9- 5, g _7. 9 ' 6 temperalure oauge - 9- 13 tum IoIgnalllghls - 9- 5, g.g warning DghlS - 9- 13 ""';ring diagrams - 9- 25 fit seq El&etricity - 0- 10 Engine numbet's ·0' 11 engine 011 pressure cl>e<:k • 1' 30

Engine, clutch and transmission - 2' 1 at seq a llernalordl1ve shatt· 2' 56 cam chain, 1&nS1oner and guides· 2'1 3, 2'44 eamshallS and followers - 2' 14

dutch - 2. 30 dutch blooding - 2. 37 dutch mastflO' cy\Ifld8r - 2 ' 34 clutch..,1east! mechanism - 2' 34, 2' 36 connecting rods - 2' 45

crankcase haNes - 2' 41,2' 43 aanks.haft - 2. 47 cy1inder block - 2' 26 c:yIioder head - 2'1 9, 2' 22

REF-51

REF' 52

Index

~WId-ooly-2' 10

~ IirIMge - &020 "..;"pm - 6023, 6024 F.... MduNUSflySr..... _4 " Ittaeq _filler housing. 4 06 air/!uel mlxt .... " -'i....1rT$"lt • 4 06 carbuMtton; - 401, 407, 4. g, 4"4, 4"6 choke cable· 4 ' 21 e>d "'PW - 4'4 , 4>6 IUillIap • 4' 4 lull ~ 1Ight....:l...ar. 4'26 ...... -4· 22 Ihn:JttII; cebIeiI • 4' 20 Fuel checks · 00 16

~~-2 .37

idWreducfion 11M< - 2' 56

m.in '-1""",2 045,2 047 ail oooIer - 2011 ail pump- 2038 ojI

Iu.. ..... • 2' 40

ail lUmp • 2040

pillIon rings - 2' 2$ pIsIone - 2027 PI'MaIflI relief vatv. • 2 0 40

_.

retnOYIOI ....:I1nst.a.tIon - 20a

..........g_'" prooIdure. 2 0 57 .-.ctor chm.,..;j forb - 2 055

_ . ctJIctI - 2056 aft. ~. 2057 tranIITdaion Ihafts· 2049. 2050 \/IIIIIe_·2 o \I

_-up

~

Mlts/IIaIIIe guides - 2-22

F.... t.o.....-.. ·l · 31

~_1 . '5.1 ' 23

IewI chick - ()ol2

Elt/wIu,' ~tem removal and installation - 4022 EXUP lyatem cable rene~, checIt, removal and install8tion · 4023 cher;k-1 - 14

F

F~..,.;I

bod)'

~

....... v.. and

Ins~

- 8 02

F.ult1lndlttQ - REFo30 Itt aq

....• -"'2

~~ ....

F...n RrtdIrtg

·9' 3

1r~1

- REFo42 1M SIOQ

01·1 ' 23

.,.... drt'ItI chick, - 0016

Fh · ()010 Foou.m, b.. ka pedal lind gearct..ng
,...,

adjustments - S021 dlsasMmbIy, n.p.ctIon and reassembly. S· 8 01 cI\angI' - 1' 3 1 ....--.I 80d installation - 606

F...... WId ........... t..n - 0 ' 11

F-....,.nslon and tinaldrlIIe· 6°11K Mq br1oke ........ ·606 braD .,..,.. - a.3 chIin·6 0 25 o;:IuIch ...... ·6ot1 drIvto cI\aIn - 6025

Fuelle¥eI check - 4" 6 F.... pump and relay chKk. _ _al and Installation - 4' 25, 9" 6 Fuel ......... awllctl · 4' 26 Fuel slralnerlfllter c:lunlng lind renewal · Fuel system check · 1'1 3 Fuel tank cleaning end repP' 4' 6 r1IITl<>YilI and n.teIIIotlon, 4' 4 Fuel tap removal end Installation , 4·. Fuel w8fl'llng lighl end _ check and.-wel · 4' 26 F_·(lo10 F.... check end ...-.I . g' 4

"'4

G

~"""

_ _alend~·604 GeardIange rnec:haniRn removal, inspection end InsIabtIon • 2' 37

H

Handlebar ,wi1<:1>n check· 9'15 removal and Inslalillion • 9' 15 Handlebarll Ind IeYerlI '_11 encIlnst.'latlon· 6' 5 Headlight IlIIT1 cI-..:Ir..-.d 1djus1"*11 ' 1. 211

--.bIy...-noYlll Mel installatIOn' 9' 1

buIb"--- . 9' 5 cIw;t<,9oS

....-aI·9· 5 Hom check and'-"-" · 9' 18 KT eoIIs checIl. removal lind IrmIIIatIon • 5<3

~·6·3

Iofka - 6<6. 6°8, 6021

tr.m.- 603 ~."""-6· 4

handlebets·6 0 S

rubberdarnpers - 6 027

shock.tleorbet - 6019, 6021 IidMtand - 6*4 eprockels· 6026, 6027 tI..w>g t-..:I bNmgI; - S' 18 lII~stem-6 ' 16 ~~_ &o21

lden1lflcltlon numbefs · (loll Id'- speed check Ind IdjuStment ' 1" 0 Idle/reduction g.ar removel, lnapection and Installation , 2' 56 Ignition (malnl l wllch check, removal and In.taUllion • 9' 14 Ignition control unit check, . _ a l and installation · 5' 4 ignition 5)'SIIfm - 5', ., MIl' cI-..:Ir. ·5' 2 controIlnt • 5' 4 HT coiIt • 503 picIc-up coil ' 5' 4

Index tIYottle ~ sensor • 5' 6 !lmIng - S
removal and InstaliaHen - gog

bulbl_ai·gog CitCuit check - gog light. check· 90S

"'""""*'"

light ~..--aI - 9013 check 80d ...-aI - 9012 rwmo'oI.""; nstaDatJon - 9 ' 11

Introduction - 004

L

LHkage Iftl - 9023 .. ~ loAd N!tIt)' ct>ecka · 0016 L _ pIvob lubr1catlon • \ 020 I..k:ence plate bulb...-. - 907 I..igh1IfIII and IIIgnailing c:twcb - ()ola, 905 ~ -1 ' 8.REF' 21

M

~.7 ·8.1 · 12

duto;:h -2034 Muter cylinder Hals . _wII brake· ,. ~

clutch· ' °25 MI~

p Iron! - 702 rea.-_7 0 9

PIck-up coli check and _ ..... - 504 PIston rlngl inIpoIctlon..-d installation - 2 029 PlstOlll....-nov... lnspectlon and installation - 2021 PrnII.n r.l1ef ~ ......,..... inspection and InsUIbtIon - 2 0 40

R

Radialor prelllU ... ClOP c"-ek 302 Rldialor .-.movil llId Inllallatlon - 306 Regulalor/re-cllflel' check. remO'ial Bnd Inllalhttlon - 9023 Relays chICk and .....ewal fuel pump - 9018 oiI~~-9018

SIartw- 90111 !ItarI... dn':uiI eut-oll - 9011

mocNnItm (clutchl rerntI'>'ai. ~.-.d InIIlIlllatJon - 2034

~

..-aj-\ 025

MalnbNringa gtntr'aIlntormallon - 2045 oil clearance check - 2048 rarnovaI,lnspIction and instaIIItion - 2 '~7 . . . MIectlon - 2048 MaintenM'lOe schedule - 104 Muter C)'IindoIor .....oval, 0¥efNtuI and lnflaI.. tion

_val and installation · 80S

MOT rnt Chld
.......... 80d inatabtlon - 806

N

,wttch check, _ V I ' It>d Inltalletlon • g'1 6 Number plata bulb renewal · 9. 7 Nut, and bolt. tighlne$s a..ck • \0 16 N .........

o

01/ cooler r.moval and inll\.llLatJon • 2° "

'"

~-(1012, '· 'S.1 ·23

/arb - \ - 31

011 nit., on "viti

- 1023

Hn_ and relay clMock, removal and Installation - go18

reeisl or checl\ and renewal - go 18

011 pre..ura check - ' °30 011 p!.Imp r.moval. inspection and "'-taulttlon • 2038 Oil atnl.- ............ , InspKtlon and inatllllation - 2040 OiIllUmp _ I I I, inspection and Installa1lon - 2040 Output tnt - 9 023

REF- 53

Routine mainl_ .nd Seivicing - 1°lal seq llirfi~ ... - 1012 alternator - '029 baltety - 1011 btake l1uid - 103 tnke hoeeI - 1029 brake mast. cyIinOw - ' °25 btake pedI_ 1018

brake I)"SI"'. 10 18 braKes - 1025 cables - 1020 carbutettcn - 1010 cham - \ 03, 101 choke cable - ' ° 19 clutch -1 011, 1025 clutch I1uid - 103 ckJtch " - - \ 029 ckJIch master cyIindw .-.d release rnect.nIIm - \ 025 COClIaoI - 103 cooling svstem - 1° 18. 1 024 cyflnder compreuioo1 - \ 030 d!tv9cha1n - ' °3, 101 .-.gina 011 ptWIII.n. 1030 enginellrammlsslon oil and fi~er - '015. 10 23 EXUPsystam·l o 14 for1
Index

REF. 54

swngwm '"" suspalSlon IInkagR bearings - " 25 lhroItIIoeMllM- "1 9 ~-"17

............._- '·25

handlebar· 9', 5 Ig n~ ion (nwn) - g. , 4 neutral - 9" 6 lidestaod - 9-0'11

wIlMI
Rubber dampel1l check and ~W1II . 6' 21 ~

- 2' 57

T

S

Safet)rf'ntl -()o 10 ItIbMta. - ()olD bIInery - 0' 10

Tact>ome1 ... ~ " " " _ a l - 90 '3 TeN light assembly remoYJII JInd InsUOllldion - 9' 8

bulbs ~aJ _ 901

checka·0· 18 electrlo;;lty - 0" 0 1Irto- Qo 1() rum.·Q· IQ Seat QOwIIng - 8' 4 s..u.-val WId 1nstaoI~ - 8" Selector dn.Im ..,.;I forb n.p.ctIon aod NtabtIon - 2' 55

-

......-*"'_ -

,,-.a.

8Idto _ _ • 8' 2, 8'4 SIdelight bul b....-al· 9' 5

.........

....--al-9· 6 che<;k _ "16

"...

ap.r. parb, _ ()o tt

QII'II·Ooll1 c:hffCk • 1· 11

g.,

._aI .

~ and Installation· 1 checII and renewal - 9" 2 Sprockllt coupling/rubber dampel1l check aod 8' 27 8pfoctIm check aod ...--., . ' . 1, 6' 26 SQnd k>brieoolion • "20 .st.rt.r circuli cvt-off relay check and...-81 · 9017 s _ clu'tcto rtII'I'IO\'lII, inspection aod Inf;tMIation . 2' 515

insj»ctJon and reusernbIy. 9' 20

.-naval_Old installation - 9020 StI"... r~.~ check and ' - - . ' ·9" 11 Start-up art... ovem.ul - 2' S7 Ste.rlng check •• 0" 6 Ste.tne head bearing. fIwpIay check and Idjustmenl • "21 Inepection and ~ - 6" 8

_

~- 1'2S

... .....

S~ stem ......ov.I aod iMt8IIMion • 6' 18 Sro..ve - REF' 27 et ~

~tment.·

6· 21 checlq· Qo1 6, "20 Su~nalon link. bMr\ngI re-greaslng. " 25 linkage r.roval, IfllPlClkln and ....tallltlon - 6· 20

........

bMMDt~- 1'25 ~Ind~,.--.I~ and hstallMion - 6"23

~c.tIIH -",g

cin:uil.d'-* -g. g Ights d'-* - 905

..... plug. gap check and adJUS'rMnl · ,.g

--

TempertItuR geuge end - - . . check end .-wal - 3 ' 4 ThermostM I'IouIIng .nil the<'mosUt remov" , ehffCk end In$tal'-tion - 3*4

bulle ___ • 9· 9

. - . . and installation - 6' 4 .wild! check 8fId _ _ • a.1 8 SIgnIoIIng cMcIo;. - (lo IS SM.nc« - 4' 22

_'w cable

check - 9' 5

Technlc.1 T _ EJlpJeln«l - REF· 46 ., seq

......,...., .00 Ir..taIetlon - 4' 20 Throttloo IIO'ItI<>n .......... check. ~ and . . . -.. - 506 TIming g.en.1IIlnlormMlon and check · 5_5 Tools end Wor*ahop 77ps - REF·2., seq T ......."..,sslon .t\ett. d~, Inspection and reassembly. 2- 50 ...-novtoI and n tdation· 2' 49 Tum signal ~....aYe! and 1nsteIa1lon· 9' 9

6' 2 1

1WTlOY8I,Inepectim and inst8IIsIlon. 8' 1$

~.

br8I<e light '11" 0 coaling I.., - 3. 2

IueIr_ - 4. 2t\

wtIefj beMngs - "17

RunnInsl-In

.-

6' 24

"'-'ks- 0"

11 ger«allntorm.llion and lilting - 7. 2,

pressures-O" S IrNd $pth. 00' 11

v

v..... _

,-

~

~

end In,;talLe1Ion · 2' "

en.ek ..-Id IidiuStment - "25

~,n.p.etlon

lind _ I l l y - 2. 22

seMcing - 2' 22

W

W.mingllghb bub..-.l- 9', 3 d'-*-9' 5 Weier pump c:hffCk. ....-.-.I. Hal and bNring .--al, and Installation - 3-6

.......

WeIOhb - REF" alignment check - 7" 5 bearings - , ' 11,

c:hffCk _ "17

" '8

Inspection and _ _ - 7" 4

remoYJII.-.d nstabtion - 7' \11, 7" 7 Wondshield ..........aI end Installation • 806 W"wing ~ - 9. 25M seq Worbhop 11» - AEF' 2 M seq

Yamaha YZF covered by this manual: YZF750R 749cc '93 to '98 YZF750SP 749cc '93 to '97

YZF1 000R Thunderace

1002cc

'96 to '00

Note: The R1 is not included in this manual

Whether carrying out a routil18 service or rebuilding the engine, Haynes SHOWS YOU HOW and SAVES YOU MONEY.

H.yOMS Hln• • and Tool TIps 11M! you Ylluabkl"ilUilde' informatIOn such as ways ~ removing pllfts without using apeckal toot • .

Inside this Manual • Model his tory and PN-ricM Checb '"' c~ • A complete step-by·step gol(le to Hrlriclng and routine rmtIntenllnce

• E...I... and t •..,..-us-'oft - seMdng and twerhaul. • Cooling system - checks and remedies • F-' aod ignition sy, t_ expIaI1ed • Suspension MId , te.Ing - ~ and O'IeI"haul

• . . . . . system - safety checks and repa.rs • Electrical s ystem - lault finding and repairs

--

• Compreh&nSiVe col_ wiring - . . - . • 18 page Tool' & Work..... TIps sectIOn In cot.. • Feuh ...... cI"IIckIist and equ.pment to ponptwII • Fu"y . . . .ed to ~ you lind inIOtmabOn easily

These Manuats are essentIal reading for any bIker tackling hIS own servicing M"I 'c~c <' N .. ,,~

•• .1 couldn t /lve WIthout my Haynes 5lpe

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